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2015-01-27 - AGENDA REPORTS - MCI CNTRT CNG COMM BUSES (2)
Agenda Item• 11 CITY OF SANTA CLARITA 0 AGENDA REPORT CONSENT CALENDAR j CITY MANAGER APPROVAL: �t7� DATE: January 27, 2015 SUBJECT: AWARD CONTRACT TO MOTOR COACH INDUSTRIES (MCI) FOR THE PURCHASE AND DELIVERY OF FIVE (5),45 -FOOT COMPRESSED NATURAL GAS (CNG) -POWERED COMMUTER COACHES DEPARTMENT: Administrative Services PRESENTER: Adrian Aguilar RECOMMENDED ACTION City Council authorize the City Manager or designee to execute a contract with Motor Coach Industries (MCI) for the purchase of five (5), 45 -foot CNG powered buses, in an amount not to exceed $3,720,000. BACKGROUND Santa Clarita Transit has a fleet replacement program that meets the Federal Transit Administration's 12 -year life cycle for transit vehicles. Five of the City commuter buses have reached their useful life and are scheduled to be replaced over the next 18 months. With approval of this action by Council, the City will be able to replace a number of aging buses that have reached the end of their useful life and take advantage of recent developments in engine technology to begin the process of replacing older, less -efficient diesel -powered commuter buses with clean -burning CNG vehicles. The City's local transit fleet is composed of all CNG buses; however, this will be the City's first purchase of CNG -powered commuter buses which will contribute to reducing emissions and improving fuel economy. The recommended action would also bring the City more in line with the desired capital replacement schedule in which approximately 1/12 of the transit fleet is scheduled for replacement each fiscal year. In late 2013, the City partnered with Victor Valley Transit Authority, Antelope Valley Transit Authority, Monterey -Salinas Transit, and Ventura County Transportation Commission to issue a Request for Proposal for the manufacture and delivery of commuter buses. Under this joint agency procurement, all five partners collaborated to establish design specifications and listed quantities of the vehicles needed over the next five years. Bidders were asked to submit fixed unit pricing for each vehicle and provide line -item pricing for optional AP g ��O Pa Packet Pg. 69 features such as bicycle racks, onboard camera systems, and fareboxes. An evaluation panel consisting of one representative for each participating agency reviewed and ranked the proposals submitted. Based on the recommendation of the evaluation panel, Victor Valley Transit Authority, acting as the lead agency, negotiated and awarded a five-year contract to Motor Coach Industries for the manufacture and delivery of commuter buses. By partnering with other transit agencies, the City was able to share the costs associated with this extensive process with multiple agencies. It also allows the partner agencies to negotiate pricing based on a much larger procurement, further reducing costs. As an added measure, staff conducted a price analysis to ensure the proposed pricing is within industry standards and is the most advantageous to the City. The joint procurement approach to acquisition is prevalent within the transit industry and is accepted by the Federal Transit Administration. ALTERNATIVE ACTION Direct staff to reissue a Request for Proposal for the procurement of five, 45 -foot CNG - powered commuter buses. 2. Other action as determined by the City Council. FISCAL IMPACT There is no impact to the General Fund with this procurement. The City has programmed Federal 5307 transit grant funds to cover 80% of the total contractual cost of the buses, and the remaining 20% required local match will come from Prop C Municipal Operator Service Improvement Program (MOSIP) funds. Adequate funds are available in the Transit Automotive Equipment Account 12400-5201.003. ATTACHMENTS RFP 2013-04 Technical Proposal for Commuter Coaches - Motor Coach Industries, Inc. (available in the City Clerks Reading File) RFP 2013-04 Price Proposal for Commuter Coaches - Motor Coach Industries, Inc. (available in the City Clerk's Reading File) Page 2 Packet Pg. 70 VICTOR VALLEY TRANSIT AUTHORITY TECHNICAL PROPOSAL COMMUTER COACHES MCI D4500 Reliability Driven - October 31, 2013 Mr. Kevin Kane Executive Director Victor Valley Transit Authority 17150 Smoketree St. Hesperia, CA 92345-8305 Subject: Request For Proposals (RFP) No. VVTA-2013-04 Dear Mr. Kane: In response to Request For Proposals (RFP) No. VVTA-2013-04 Motor Coach Industries, Inc. (MCI) is pleased to submit its RFP 2013-04 Technical Proposal for Commuter Coaches. This letter and the documents attached hereto constitute MCI's Technical Proposal. Attachment #1 Technical Proposal Attachment #2 References and Non -Priced Information Attachment #3 Forms, excluding Pricing & Warranty Information Attachment #4 Supporting Data Technical Proposal & Product Evaluation (Items A thru P) Attachment # 5 Supporting Data Proposer Qualifications Statement (Items A thru J) We appreciate the opportunity to submit this bid and look forward to being called upon to fulfill your equipment needs. Sincerely, Pat ck Scully Executive Vice si Sales and Marketing Motor Coach Industries ! 200 East Oaklon Street I Des Plaines, Illinois 60018 1847 286 2000 1 866 624 2622 TO Free www.mcicoach.com Reliability Driven' ATTACHMENT # 1 TECHNICAL PROPOSAL 1.1.5.27 OFFER COVER SHEET Proposer shall complete the following form and include same in BOTH the technical and price proposals. By execution below Proposer hereby offers to furnish equipment and services as specified in Victor Valley Transit Authority's Request for Proposals No. RFP 2013-04 at the prices set out in the pricing schedule. Proposer Company Name: Street Address: City, State, Zip: 200 East Oakton Street Des Plaines, IL 60018 Signature of Authorized Signer: Patrick Scully Title: Executive Vice President Sales and Marketing Phone: 847-285-2354 Section 1 — Page 56 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129113 1.1.5.25 TECHNICAL PROPOSAL Proposer shall complete the following form and include same in the Technical proposal. By execution below Proposer hereby agrees to furnish the Commuter Coaches, related equipment and services as specified in Victor Valley Transit Authority's Request for Proposals No. 2013-04, submitted in response to the technical portion of the solicitation. VVTA - RFP 2013-04 TECHNICAL PROPOSAL PROPOSER COMPANY NAME: Motor Coach Industries, Inc. STREET ADDRESS: CITY. STATE. ZIP CODE: AUTHORIZED OFFICER COMPANY OFFICER TITLE: SIGNATURE OF AUTHORIZED CONTACT INFORMATION: OFFICE PHONE NUMBER EMAIL ADDRESS: 200 East Oakton Street Des Plaines, IL 60018 Patrick Scully Executive Vice Dave Dorr 818-519-5032 dave.dorr@mcicoach.com Sales and Marketing Section 1 — Page 54 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 5.0 TECHNICAL AND PERFORMANCE SPECIFICATIONS TS- 01 THROUGH TS -79 Section 5 — Page 1 VVTA Solicitation No. 2013-04 Rev 4 Dated K29/13 TECHNICAL AND PERFORMANCE SPECIFICATIONS TABLE OF CONTENTS 5.0 TECHNICAL AND PERFORMANCE SPECIFICATIONS ,_~,__.,,°°~_...°°.~^~~~~°°~^~'~"~.~^°.~~-.°~~°°.% 10TS-1SC0eE..........._~-.-..............,~~~~...-~...~~_.^~.~'~.^-^..~..~.~ TS -2 DEFIN177ONS 7S-3 REFERENCED PV8UCAnONS............................................ -~~^~~_~~~........ ........................ .................. ... 16 7S-4 LEGAL REQUIREMENTS ..................... ...................................... ............. ~~^~~^.,.'-~.............................. ......... 16 73-5 OVERALL REQVKD9N8V72..............-.~....^..^-~~~~~~'^~~~^~~~.~~~'-~~~~ zr CS -5.1 WEIGHT .................................. ................ ................................................ .... .................................. .............. 17 CAPACITY .....-..-.-.......-...~.-.^~.,.--~~~----~~~~.~.~~~~.-.._ 17TS-5.2 TS -5.3 SERVICE LIFE .............................................. ............ .......................................................................................... 17 TS' /| MAINTENANCE AND INSPECTION ....................... _............. ........................................................................ 17 `S'.5 |NTEn[HANGEx8inv.................................................. ............ ................................. ............................... ..... 10 TS -5/6 TRAINING .............. ................................................................................... ...................................................... 18 .6.1 T[CHNKJ\bS[KV|CEREPR[3ENTA�VES....^°..-......,_~-.^..~..--^~^~~~~~~^.^^ isl3^ }S'5.7 OPERATING ENVIRONMENT .................................................................. ............... .................................. ..... 19 7S-5& NOISE ...................................... ~........................... .......................................... ~~~—.--19 TS' J8.1 INTERIOR NOISE ............................................................................................................................................ 19 73-5.82 EXTERIOR NOISE .................................................................................................................................. ........ 19 T3-5.9 FIRE SAFETY ......................................................... ...................................................................... ...................... 19 73.5.91 MATERIALS ................................................................................................................... ............................... 19 TS'.10 FIRE SUPPRESSION ................................. -............ ~............................................................................. -............. mo TS -5J1 RESPECT FOR THE ENVIRONMENT .................................................................................................................... zo 7S*6 PHYSICAL SIZE ................................................ 2" 7S-6.1 COACHL[N6TH........................................................................................... ..................................................... z1 TS -62 COACH WIDTH ......................... ............... . ...................................................................................................... 21 TS -6.3 COACH HEIGHT ................................................................................................................................................. 21 TS -6/4.1 STEP HEIGHT .......................................................................................................... ................... ................ 21 TS - 6.5 UNDERBODY CLEARANCE ................... ............................ .................................................................... .......... J1 Ts' .6 RAMP CLEARANCES ............................................................................................... .......................................... 21 T5 -6J GROUND CLEARANCE .... .................................................................................................................................. 22 TS -6.8 FLOOR HEIGHT ............................................................ ...................................................... ............................. zs TS -6.9 INTERIOR HEADROOM ......................................................... ............................................................................ /» 7S^7 P0N/8Y ..~..._..-~~~..~~.~'.~~~^.....~..~-.~~^~~...~..^.~.~_~.~23 TS7.1 TOP SPEED ...................................... _ ~~~..'~~_°~.~23 TS7.2 GK^oxmuTv.................................................................. _.................................................... ........................... 24 7S711ACCELERATION ....................... ..................................................................................................................... 2u TS7.2.2 NON -HYBRID ................................................................................................... ............................................. Zu 7373 OPERATING RANGE ................................................ ~~.~-~~^.~~~~--~~.~~.-~~..~^-~.-~.24 Section 5 - Page 2 75-8 FUEL ECONOMY (DESIGN OPERATING PROFILE) TS -9 ENGINE ................... TS 9.1 ENGINE (CNG) 15 15 26 TS -10 COOLING SYSTEMS................................................................................................................................................ 26 TS10.1 ENGINE COOLING ............................................. ....................... _............................ ............ _.............................. 26 TS10.1.1 COOLANT...................................................................................................................................................... 26 TS10.1.2 DRIVE DESIGN...............................................................................................................................................27 TS10.1.3 MOUNTING................................................................................................................................................... 27 TS 10.2 TRANSMISSION COOLING................................................................................................................................. 27 TS -11 TRANSMISSION (CONVENTIONAL POWERTRAIN)................................................................................................. 17 TS -12 RETARDER (CNG) ................... .... _.................................................................................................. _................. _... 28 TS -13 ENGINE BRAKE (DIESEL) TS -14 MOUN77NG TS 14.1 SERVICE., 28 28 28 TS -15 HYDRAULIC SYSTEMS............................................................ ...... ................. ......................... .............................. ... 19 TS15.1 FLUID LINES......................................................................................................................................._.............. 29 TS15.2 FITTINGS AND CLAMPS..................................................................................................................................... 29 TS15.3 CHARGE AIR PIPING.......................................................................................................................................... 30 TS -16 RADIATOR.............................................................................................................................................................. 30 TS -17 OIL AND HYDRAULIC LINES .................................................................................................................................... 30 75-18 FUEL....................................................................................................................................................................... 30 TS18.1 FUEL LINES........................................................................................................................................................ 30 TS18. 1.1 FUEL LINES, DIESEL .................................. _................................................................................................... 31 TS 18. 1.2 FUEL LINES, CNG...........................................................................................................................................31 TS18.2 DESIGN AND CONSTRUCTION ....................... _........................................................................ .......................... 32 TS18.2.1 DIESEL FUEL TANK(S).................................................................................................................................... 32 TS 18.2.2 DESIGN AND CONSTRUCTION, CNG............................................................................................................. 32 TS -19 EMISSIONS AND EXHAUST..................................................................................................................................... 34 TS19.1 EXHAUST EMISSIONS........................................................................................................................................ 34 TS19.2 EXHAUST SYSTEM............................................................................................................................................. 35 TS19.3 EXHAUST AFTER -TREATMENT ........... ................................................................................... :..... ...................... 35 TS 19.4 PARTICULATE AFTER-TREATMENT(DIESEL)..............................................................................._..................... 35 TS -20 GENERAL..............................................................................................I............. TS20.1 DESIGN.......................................................................................................... 35 35 TS -21 ALTOONA TESTING .................................. ......................... ........... .............. ........................................................ I... 35 TS 21.1 STRUCTURAL VALIDATION............................................................... _._............................................................ 36 TS -21 DISTORTION........................................................................................................................................................... 36 TS -23 RESONANCEAND VIBRATION................................................................................................................................ 36 TS 23.1 ENGINE COMPARTMENT BULKHEADS.............................................................................................................. 36 Section 5 — Page 3 VVTA Solicitation No. 2013-04 Rev 4 Dated 829/13 TS23.2CRASHWORTHINESS......................................................................»..........................................I...................... 36 TS -24 CORROSION .......... ................................................................. ...... ..................... ._............................................... .... 37 TS -25 TOWING.................................................................................................................................................................37 TS -16 JACKING ................................................................................................................................................................. 37 TS -27 HOISTING...............................................................................................................................................................38 TS -28 FLOOR.........................................................................................................................................................I.......... 38 TS28.1 DESIGN.............................................................................................................................................................. 38 TS28.2 CONSTRUCTION ........................... _........................................................................................................... ........ 38 TS -29 PLATFORMS........................................................................................................................................................... 39 TS29.1 DRIVER'S AREA......................................................................».......................................................................... 39 TS29.2 FAREBOX........................................................................................................................................................... 39 TS -30 WHEEL HOUSING............ ............................................... .................................................................................. ...... 39 TS30.1 DESIGN AND CONSTRUCTION........................................................................................................................... 39 TS -31 SUSPENSION.......................................................................................................................................................... 39 TS31.1 GENERAL REQUIREMENTS................................................................................................................................ 39 TS31.2 ALIGNMENT...................................................................................................................................................... 39 TS31.3 SPRINGS AND SHOCK ABSORBERS ............................... ....... _............................................................................ 40 TS31.3.1 SUSPENSION TRAVEL.................................................................................................................................... 40 TS31.3.2 DAMPING...................................................................................................................................................... 40 TS31.3.3 LUBRICATION..........................................................................................................................._................... 40 TS31.3.4 KNEELING...................................................................................................................................................... 40 TS -31 WHEELS AND TIRES............................................................................................................................................... 41 TS32.1 WHEELS...........................................................................................:............_................................................... 41 TS32.2 TIRES................................................................................................................................................................. 41 TS -33 STEERING...............................................................................................................................................................41 TS33.1 STEERING AND TAG AXLES................................................................................................................................41 TS33.2 STEERINGWHEEL.............................................................................................................................................. 42 TS33.2.1 TURNING EFFORT......................................................................................................................................... 42 TS33.2.2 STEERING WHEEL, GENERAL........................ ................................................................................................. 42 TS33.2.3 STEERING COLUMN TILT............................................................................................................................... 42 TS 33.2.4 STEERING WHEEL TELESCOPIC ADJUSTMENT ............................................... _............................................ 42 TS -34 DRIVEAXLE.... TS 34.1 NON -DRIVE CJ TS -35 TAG AXLES (COMMUTER COACH) ......................................................................................................................... 43 TS -36 TURNING RADIUS.................................................................................................................................................. 44 TS -37 BRAKES ....................... __....................................................................................................................................... 45 TS37.1 SERVICE BRAKE................................................................................................................................................. 45 TS37.2 ACTUATION....................................................................................................................................................... 45 TS37.3 FRICTION MATERIAL.........................................................................................................................................45 TS37.4 HUBS AND DISCS............................................................................................................................................... 45 Section 5 — Page 4 V VTA Solicitation No. 2013-04 Rev 4 Dated 829113 TS 37.5 PARKING/EMERGENCY BRAKE ................... _............... ........... .................................... _..................................... 45 TS -38 PNEUMATIC SYSTEM ..................................... ............... _............................. ................ _.................... .................... 46 TS38.1 GENERAL......................................................................................._.................................................................. 46 TS38.2 AIR COMPRESSOR............................................................................................................................................. 46 TS38.3 AIR LINES AND FITTINGS................................................................................................................I....I....._...... 46 TS38.4 AIR RESERVOIRS................................................................................................................................................ 47 TS38.5 AIR SYSTEM DRYER........................................................................................................................................... 47 TS -39 OVERVIEW ................. TS 39.1 MODULAR DESIGN 47 48 TS -4O ENVIRONMENTAL AND MOUNTING REQUIREMENTS........................................................................................... 48 TS40.1 HARDWARE MOUNTING................................................................................................................................... 49 TS -41 GENERAL ELECTRICAL REQUIREMENTS................................................................................................................. 49 TS41.1 BATTERIES......................................................................................................................................................... 49 T541.1.1 LOW -VOLTAGE BATTERIES(24V)....................... _........................................................................................ 49 TS41.1.2 BATTERY CABLES........................................................................................................................................... 50 TS41.1.3 JUMP START ........................... ».._.................................................................... ............................................. 50 TS41.1.4 BATTERY COMPARTMENT .......... .............................. .................. _................................................................ 50 TS 41.1.5 AUXILIARY ELECTRONIC POWER SUPPLY...................................................................................................... 52 TS41.1.6 MASTER BATTERY SWITCH ................................ ........... ...... ........... _........................... ................................ 53 TS 41.1.7 LOW -VOLTAGE GENERATION AND DISTRIBUTION........................................................................................ 53 TS41.1.8 CIRCUIT PROTECTION................................................................................................................................... 53 TS41.2 GROUNDS.......................................................................................................................................................... 54 TS 41.3 LOW VOLTAGE/LOW CURRENT WIRING AND TERMINALS............................................................................... 54 TS41.4 ELECTRICAL COMPONENTS....................................................».......................................................................... 55 TS41.5 ELECTRICAL COMPARTMENTS..........................................................................................................................55 TS -42 GENERAL ELECTRONIC REQUIREMENTS.._............................................................................................................56 TS42.1 WIRING AND TERMINALS.................................................................................................................................. 56 TS42.1.1 DISCRETE I/0(INPUTS/OUTPUTS)................................................................................................................ 56 TS42.1.2 SHIELDING .......... .......... _...................................................... ........................................................................ 56 TS42.1.3 COMMUNICATIONS...................................................................................................................................... 56 TS42.1.4 RADIOFREQUENCY(RF)...................».................»...............:....................................................................... 57 TS42.1.5 AUDIO.............................................................................................................»............................................ 57 TS -43 MULTIPLEXING...................................................................................................................................................... 57 TS43.1 GENERAL ........................................... _.............................................................................................................. 57 TS43.2 SYSTEM CONFIGURATION................................................................................................................................. 57 43.2.1 1/0 SIGNALS...................................................................................................................................................... 57 TS -44 DATA COMMUNICATIONS ..................................................................................................................................... 58 TS44.1 GENERAL........................................................................................................................................................... 58 TS44.2 DRIVETRAIN LEVEL............................................................................................................................................ 58 TS 44.2.1 DIAGNOSTICS, FAULT DETECTION AND DATA ACCESS................................................................................. 58 TS 44.2.2 PROGRAMMABILITY (SOFTWARE).. .............................................................................................................. 58 TS44.3 MULTIPLEX LEVEL......................................................................................................................_...................... 59 TS44.3.1 DATA ACCESS................................................................................................................................................ 59 Section 5 — Page 5 VVTA Solicitation No. 2013-04 Rev _.L_Dated 8)29113 TS 44.3.2 DIAGNOSTICS AND FAULT DETECTION ......................................................................................................... 59 TS 44.3.3 PROGRAMMABILITY (SOFTWARE) ................................................................................................................ 59 TS 44.4 ELECTRONIC NOISE CONTROL................................................................................................................................ 60 TS -45 DRIVER'SAREA CONTROLS.................................................................................................................................... 60 TS45.1 GENERAL......................................................................................................................................_................... 60 TS45.2 GLARE..................................................»............................................................................................................ 60 TS45.3 VISORS/SUNSHADES........................................................................................................................................ 60 TS45.4 DRIVER'S CONTROLS......................................................................................................................................... 61 TS 45.5 NORMAL COACH OPERATION INSTRUMENTATION AND CONTROLS............................................................... 61 TS45.6 DRIVER FOOT CONTROLS.................................................................................................................................. 69 TS45.6.1 PEDAL ANGLE..................................................................................................................I............................. 69 TS 45.6.2 PEDAL DIMENSIONS AND POSITION............................................................................................................. 70 TS 45.7 DRIVER FOOT SWITCHES.............................................................................._............._....................................70 TS -46 DRIVER'SAMENMES............................................................................................................................................. 70 TS46.1 COAT HANGER.........................................................................................................._...................................... 70 TS46.2 STORAGE BOX .................... ................................................. ................ _................ ............................................ 71 TS -47 WINDSHIELD WIPERS AND WASHERS................................................................................................................... 71 TS47.1 WINDSHIELD WIPERS........................................................................................................................................ 71 TS 47.2 WINDSHIELD WASHERS.................................................................................................................................... 71 TS -48 DRIVER'SSEAT.......................................... _............................................................................... _....... .—..... ......... 71 TS48.1 DIMENSIONS......................................................................_..........................................................I.................. 72 TS48.2 SEAT BELT ............................... _....................... ...................... ............................................................................ 72 TS48.3 SEAT CONTROL LOCATIONS ....................... _..................................................................................................... 73 TS 48.4 SEAT STRUCTURE AND MATERIALS................................................................................................................... 73 TS48.5 PEDESTAL.......................................................................................................................................................... 73 TS48.6 SEATOPTIONS...................................................... _.... ...... .................................... __............ ........................... 73 TS48.7 MIRRORS........................................................................................................................................................... 73 TS48.7.1 EXTERIOR MIRRORS .......................... ..................... _..................................................................................... 73 TS 48.7.2 INTERIOR MIRRORS..........................................................................................................................._......... 74 TS -49 GENERAL................................................................................................................................................................74 TS -50 WINDSHIELD..........................................................................................................................................................74 TS50.1 GLAZING............................................................................................................................................................ 74 TS -51 DRIVER'S SIDE WINDOW 75 TS -51 SIDE WINDOWS.. ....... ............. ............................................................................................................. ............... 75 TS52.1 CONFIGURATION.............................................................................................................................................. 75 TS 52.2 EMERGENCY EXIT (EGRESS) CONFIGURATION................................................. _.................................. ............. 76 TS52.3 MATERIALS........................................................................................................................................................ 76 TS -53 CAPACITYAND PERFORMANCE............................................................................................................................. 76 TS -54 CONTROLS AND TEMPERATURE UNIFORMITY...................................................................................................... 77 TS54.1 AUXILIARY HEATER............................................................................................................................................ 78 TS -55 AIR Section 5 — Page 6 VVTA Solicitation No. 2013-04 Rev 4 Dated/8 29/13 78 TS55.1 PASSENGER AREA...................................................................................._........................................................78 TS55.2 DRIVER'S AREA .......................................... _.............................................. ........................................................ 78 TS 55.3 CONTROLS FOR THE CLIMATE CONTROL SYSTEM (CCS) ................................................................................... 79 TS 55.4 DRIVER'S COMPARTMENT REQUIREMENTS..................................................................................................... 79 TS55.5 DRIVER'S COOLING........................................................................................................................................... 79 TS -56 AIR FILTRATION..................................................................................................................................................... 80 TS -57 ROOF VENTILATORS..................................................................................................................................I........... 80 TS -58 MAINTAINABILITY.................................................................................................................................................. 80 TS -59 ENTRANCE/EXITAREA HEATING........................................................................................................................... 80 TS -6O FLOOR -LEVEL HEATING......................................................................................................................................... 80 TS60.1 COMMUTER COACH ........................................ .... ...... .......... .................................. Errorl Bookmark not defined. TS -61 DESIGN.................................................................................................................................................................. 81 TS61.1 MATERIALS........................................................................................................................................................ 81 TS -62 PEDESTRIAN SAFETY.............................................................................................................................................. 81 TS -63 REPAIR AND REPLACEMENT.................................................................................................................................. 81 TS63.1 SIDE BODY PANELS............................................................................................................................................ 81 TS -64 RAIN GUTTERS....................................................................................................................................................... 81 TS -65 LICENSE PLATE PROVISIONS.................................................................................................................................. 82 TS -66 FENDER SKIRTS..............................................................................................._......................_............................. 82 TS66.1 SPLASH APRONS................................................................................................................................................ 82 TS -67 SERVICE COMPARTMENTS AND ACCESS DOORS................................................................................................... 83 TS67.1 ACCESS DOORS ................................................... ................................................................ .............................. 83 TS67.2 ACCESS DOOR LATCH/LOCKS.......................................... _................................................................................ 83 TS -68 BUMPERS.......................................................................................................................................................I....... 83 TS68.1 LOCATION......................................................................................................................................................... 83 TS68.2 FRONT BUMPER................................................................................................................................................ 83 TS68.3 REAR BUMPER.................................................................................................................................................... 84 TS68.4 BUMPER MATERIAL ........... ........................................ _...................................................... ............................... 84 TS -69 FINISH AND COLOR................................................................................................................................................ 84 TS69.1 APPEARANCE .......................................... ......... ................................................................ ......................... ....... 84 TS -70 DECALS,NUMBERING AND SIGNING ................. ............................. _.......... .... _............. ................. ».................... 85 TS 70.1 PASSENGER INFORMATION ................................... ....................... .......... ...................................... _.................. 85 TS -71 EXTERIOR LIGHTING.............................................................................................................................................. 86 TS71.1 BACKUP LIGHT/ALARM............................................. ........................................................... I ....... ..................... 86 TS71.2 DOORWAY LIGHTING........................................................................................................................................ 86 TS71.3 TURN SIGNALS ........................................... .................................................................................. .._................. 86 TS71.4 HEADLIGHTS...................................................................................................................................................... 86 TS71.5 BRAKE LIGHTS................................................................................................................................................... 87 TS 71.6 SERVICE AREA LIGHTING (INTERIOR AND EXTERIOR).......................................................... _...... ..................... 87 Section 5 — Page 7 VVTA Solicitation No. 2013-04 Rev _A__Dated 8/29/13 TS -71 GENERAL REQUIREMENTS..................................................................................................................................... 87 TS -73 INTERIOR PANELS ..................................................................................................................................................88 ARRANGEMENTS AND SEAT STYLE (COMMUTER COACH)............................................................................... TS73.2 MODESTY PANELS ...................... ............. ........................................................... ............................. I................. 88 TS73.3 FRONT END ..................... ...................... .................................................................................. _........................ 88 TS73.4 REAR BULKHEAD ....... ........ _.......................................... _............................................................................. I.... 89 TS73.5 HEADLINING ..................... ..................................................................................................................... _.......... 89 TS73.6 FASTENING ...................... ...................................................... .... .............................................. I......................... 89 TS73.7 INSULATION...................................................................................................................................................... 89 TS73.8 FLOOR COVERING............................................................................................................................................. 90 TS73.9 INTERIOR LIGHTING.......................................................................................................................................... 90 TS73.10 PASSENGER........................................................ .......... _.............. »......................................................... ...... 90 TS73.11 DRIVER'S AREA............................................................................................................................................. 91 TS73.12 SEATING AREAS .................................... _...................... _............. _._.... ........................................................ 91 TS73.13 VESTIBULES/DOORS...................................................................................................................................... 91 TS73.14 STEP LIGHTING...................................................... ....... ............ .............................................. I ............. _...... 91 TS73.15 FAREBOX LIGHTING...................................................................................................................................... 92 TS -74 FARE COLLECTION TS -75 INTERIOR ACCESS PANELS AND DOORS (TRANSITCOACH)........ ....... ............................... __............ ......... _...... 91 TS75.1 FLOOR PANELS.................................................................................................................................................. 92 TS -76 PASSENGER SEA TING............................................................................................................................................. 93 TS 76.1 ARRANGEMENTS AND SEAT STYLE (COMMUTER COACH)............................................................................... 93 TS76.2 HIP -TO -KNEE ROOM......................................................................................................_.................................93 TS76.3 FOOT ROOM..................................................................................................................................................... 93 TS 76.4 AISLES (COMMUTER COACH)............................................................................................................................ 93 TS 76.5 STRUCTURE AND DESIGN (COMMUTER COACH).............................................................................................. 93 TS 76.6 CONSTRUCTION AND MATERIALS (COMMUTER COACH)................................................................................. 94 TS76.7.1 FRONT DOOR................................................................................................................................................ 94 TS 76.8 MATERIALS AND CONSTRUCTION.................................................................................................................... 94 TS76.9 DOOR GLAZING................................................................................................................................................. 94 TS76.9.1 ACTUATOR (COMMUTER COACH)................................................................................................................ 95 TS76.10 EMERGENCY OPERATION............................................................................................................................. 95 TS76.11 DOOR CONTROL........................................................................................................................................... 95 TS76.12 DOOR CONTROLLER...................................................................................................................................... 95 TS -77 WHEELCHAIR LIFTS (COMMUTERCOACH).....................................................................:...................................... 95 TS -77.1 LIFT......................................................................................................................................................._........... 95 TS -77.2 LIFT DOOR......................................................................................................................................................... 96 TS77.3 LIFT WIDTH.............................................................. ....................................................... _................................ 97 TS -77.4 LIGHTING REQUIREMENTS............................................................ _....................................... ........................... 97 TS -77.5 SECU REM ENT SYSTEM...................................................................................................................................... 97 TS -77.6 ROOF VENTILATION/ESCAPE HATCHES............................................................................................................. 98 TS -78 DESTINATIONSIGNS........................................................ _......................... ........................................................... 98 TS -78.2 SIGNAL CHIME COMMUTER COACH................................................................................................................. 98 TS -79 COMMUNICATIONS ................................. ..... _.................................................................. ....................... .............. 98 Section 5 - Page 8 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29113 TS -79.1 CAMERA SURVEILLANCE SYSTEM .................................................. _...... I ...... , TS -79.2 PUBLIC ADDRESS SYSTEM............................................................................... TS -79.3 SPEAKERS........................................................................................................ TS -79.4 AUTOMATIC PASSENGER COUNTER (APC) ...................................................... TS -79.5 RADIO HANDSETAND CONTROLSYSTEM............................................. I......... TS -79.6 DRIVER'S SPEAKER.......................................................................................... TS -79.7 HANDSET......................................................................................................... TS -79.8 DRIVER DISPLAY UNIT(DDU).......................................................................... TS -79.9 EMERGENCYALARM..............................................................................I........ Section 5 — Page 9 VVTA So6cit4on No. 2013-04 Rev _A_Dated 829/13 99 99 99 99 99 99 99 99 VALLEY TRANSIT AUTHORITY COMPRESSED NATURALCaASand LOW -EMISSION DIESEL COMMUTER COACHES IRFPNUMBER:VVTA SECTION 5: TECHNICAL PERFORMANCE SPECIFICATIONS TS -1 SCOPE Technical Performance Specifications define requirements for heavy-duty commuter coaches, which, by the selection of specifically identified alternative configurations, may be used for over the road commuter trips to provide the most comfort possible for trips lasting from 1 to 2 hours. Coaches shall have a minimum expected life of twelve (12) years or 500,000 miles, whichever comes first, and are intended for the widest possible spectrum of passengers, including children, adults, the elderly and people with disabilities. TS -2 DEFINITIONS (1) Alternative: An alternative specification condition to the default coach configuration. The Agency may define alternatives to the default configuration to satisfy local operating requirements. Alternatives for the default configuration will be clearly identified. (2) Ambient Temperature: The temperature of the surrounding air. For testing purposes, ambient temperature must be between 16 °C (50 °F) and 38 °C (100 °F). (3) Analog Signals: A continuously variable signal that is solely dependent upon magnitude to express information content. (4) NOTE: Analog signals are used to represent the state of variable devices such as rheostats, potentiometers, temperature probes, etc. (5) Audible Discrete Frequency: An audible discrete frequency is determined to exist if the sound power level in any 1/3 -octave band exceeds the average of the sound power levels of the two adjacent 1/3 -octave bands by 4 decibels (dB) or more. (6) Battery Compartment: Low -voltage energy storage, i.e. 12/24 VDC batteries. (7) Battery Management System (BMS): Monitors energy, as well as temperature, cell or module voltages, and total pack voltage. The BMS adjusts the control strategy algorithms to maintain the batteries at uniform state of charge and optimal temperatures. (8) Braking Resistor: Device that converts electrical energy into heat, typically used as a retarder to supplement or replace the regenerative braking. Section 5 — Page 10 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 (9) Burst Pressure: The highest pressure reached in a container during a burst test. (10) Capacity (fuel container): The water volume of a container in gallons (liters). (11) Cells: Individual components (i.e., battery or capacitor cells). (12) Code: A legal requirement. (13) Combination Gas Relief Device: A relief device that is activated by a combination of high pressures or high temperatures, acting either independently or together. (14) Composite Container for CNG: A container fabricated of two or more materials that interact to facilitate the container design criteria. (15) Compressed Natural Gas (CNG): Mixtures of hydrocarbon gases and vapors consisting principally of methane in gaseous form that has been compressed for use as a vehicular fuel. (16) Container: A pressure vessel, cylinder or cylinders permanently manifolded together, used to store CNG. (17) Container Appurtenances: Devices connected to container openings for safety, control or operating purposes. (1 S) Container Valve: A valve connected directly to a container outlet. (19) Curb Weight: Weight of vehicle, including maximum fuel, oil and coolant; and all equipment required for operation and required by this Specification, but without passengers or driver. (20) dBA: Decibels with reference to 0.0002 microbar as measured on the "A" scale. (21) DC to DC Converter: A module that converts a source of direct current from one voltage level to another. (22) Default Configuration Coach: The coach described if no alternatives are selected. Signing, colors, the destination sign reading list and other information must be provided by the Agency. (23) Defueling: The process of removing fuel from a tank. (24) Defueling Port. Device that allows for vehicle defueling, or the point at which this occurs. (25) Destroyed: Physically made permanently unusable. (26) Discrete Signal: A signal that can take only pre -defined values, usually of a binary 0 or 1 nature, where 0 is battery ground potential and 1 is a defined battery positive potential. (27) DPF: Diesel particulate filter. Section 5 — Page 11 WTA Solicitation Na 2013-04 Rev 4 Datcd S/29r i3 (28) Driver's Eye Range: The 95th -percentile ellipse defined in SAE Recommended Practice J941, except that the height of the ellipse shall be determined from the seat at its reference height. (29) Energy Density: The relationship between the weight of an energy storage device and its power output in units of watt-hours per kilogram (Wh/kg). (30) Energy Storage System (ESS): A component or system of components that stores energy and for which its supply of energy is rechargeable by the on -vehicle system (engine/regenerative braking/ generator) or an off -vehicle energy source. (31) Fill Pressure for CNG: The pressure attained at the actual time of filling. Fill pressure varies according to the gas temperatures in the container, which are dependent on the charging parameters and the ambient conditions. The maximum dispensed pressure shall not exceed 125 percent of service pressure. (32) Flow Capacity: For natural gas flow, this is the capacity in volume per unit time (normal cubic meters/minute or standard cubic feet per minute) discharged at the required flow rating pressure. (33) Fuel Line: The pipe, tubing or hose on a vehicle, including all related fittings, through which natural gas passes. (34) Fusible Material: A metal, alloy or other material capable of being melted by heat. (35) Fire Resistant: Materials that have a flame spread index less than 150 as measured in a radiant panel flame test per ASTM -E 162-90. (36) Fireproof: Materials that will not burn or melt at temperatures less than 2000 °F. (37) Free Floor Space: Floor area available to standees, excluding the area under seats, area occupied by feet of seated passengers, the vestibule area forward of the standee line, and any floor space indicated by manufacturer as non -standee areas, such as the floor space "swept" by passenger doors during operation. Floor area of 1.5 sq ft shall be allocated for the feet of each seated passenger protruding into the standee area. (38) Fuel Management System: Natural gas fuel system components that control or contribute to engine air fuel mixing and metering, and the ignition and combustion of a given air - fuel mixture. The fuel management system would include, but is not limited to, reducer/regulator valves, fuel metering equipment (e.g. carburetor, injectors), sensors (e.g., main throttle, wastegate). (39) GAWR (Gross Axle Weight Rated): The maximum total weight as determined by the axle manufacturer, at which the axle can be safely and reliably operated for its intended purpose. (40) Gross Load: 150 lbs for every designed passenger seating position, for the driver, and for each 1.5 sq ft of free floor space. Section 5 — Page 12 V VTA Solicitation No. 2013-04 Rev 4 Dated2$ 'J/13 (41) GVW (Gross Vehicle Weight): Curb weight plus gross load. (42) GVWR (Gross Vehicle Weight Rated): The maximum total weight as determined by the vehicle manufacturer, at which the vehicle can be safely and reliably operated for its intended purpose. (43) High Pressure: Those portions of the CNG fuel system that sees full container or cylinder pressure. (44) High Voltage (HV): Greater than 50 V (AC and DC). (45) Hose: Flexible line. (46) Hybrid: A vehicle that uses two or more distinct power sources to propel the vehicle. (47) Hybrid System Controller (HSC): Regulates energy flow throughout hybrid system components in order to provide motive performance and accessory loads, as applicable, while maintaining critical system parameters (voltages, currents, temperatures, etc.) within specified operating ranges. (48) Hybrid Drive System (HDS): The mechanical and/or electromechanical components, including the engine, traction motors and energy storage system, which comprise the traction drive portion of the hybrid propulsion system. (49) Intermediate Pressure: The portion of a CNG system after the first pressure regulator, but before the engine pressure regulator. Intermediate pressure on a CNG vehicle is generally from 3.5 to 0.5 MPa (510 to 70 psi). (50) Inverter: A module that converts DC to and from AC. (51) Labeled: Equipment or materials to which has been attached a label, symbol or other identifying mark of an organization, which is acceptable to the authority having jurisdiction and concerned with product evaluation, which maintains periodic inspection of production labeled equipment or materials, and by whose labeling the manufacturer indicates compliance with appropriate standards or performance in a specified manner. (52) Leakage: Release of contents through a Defect or a crack. See Rupture. (53) Line: All tubes, flexible and hard, that carry fluids. (54) Liner: Inner gas-tight container or gas container to which the overwrap is applied. (55) Local Regulations: Regulations below the state level. (56) Low -Floor Coach: A coach that, between at least the front (entrance) and rear (exit) doors, has a floor sufficiently low and level so as to remove the need for steps in the aisle between the doors and in the vicinity of these doors. (57) Low Voltage (LV): 50 V or less (AC and DC). Section 5 — Page 13 VVTA Solicitation No. 2013-04 Rev _a Dated 8;3)'13 (58) Lower Explosive Limit: The lowest concentration of gas where, given an ignition source, combustion is possible. (59) Maximum Service Temperature: The maximum temperature to which a container/cylinder will be subjected in normal service. (60) Metallic Hose: A hose whose strength depends primarily on the strength of its metallic parts; it can have metallic liners or covers, or both. (61) Metering Valve: A valve intended to control the rate of flow of natural gas. (62) Module: An assembly of individual components (63) Motor (Electric): A device that converts electrical energy into mechanical energy. (64) Motor (Traction): An electric motor used to power the driving wheels of the coach. (65) Operating Pressure: The varying pressure developed in a container during service. (66) Physical Layer: The first layer of the seven -layer International Standards Organization (ISO) Open Systems Interconnect (OSI) reference model. This provides the mechanical, electrical, functional and procedural characteristics required to gain access to the transmission medium (e.g., cable) and is responsible for transporting binary information between computerized systems. (67) Pipe: Nonflexible line. (68) Pressure Relief Device (PRD):A pressure and/or temperature activated device used to vent the container/cylinder contents and thereby prevent rupture of an NGV fuel container/cylinder, when subjected to a standard fire test as required by fuel container/cylinder standards. (69) NOTE: Since this is a pressure -activated device, it may not protect against rupture of the container when the application of heat weakens the container to the point where its rupture pressure is less than the rated burst pressure of the relief device, particularly if the container is partially full. (70) Power: Work or energy divided by time (71) Power Density: Power divided by mass, volume or area. (72) Propulsion System: System that provides propulsion for the vehicle proportional to operator commands. Includes, as applicable, engine, transmission, traction motors, the hybrid drive system, (HDS), energy storage system (ESS), and system controllers including all wiring and converter/inverter. (73) Real -Time Clock (RTC): Computer clock that keeps track of the current time. Section 5 — Page 14 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 (74) Regenerative Braking: Deceleration of the coach by switching motors to act as generators, which return vehicle kinetic energy to the energy storage system. (75) Rejectable Damage: In terms of NGV fuel containers/cylinders, this is damage as outlined in CGA C-6.4, "Methods for External Visual Inspection of Natural Gas Vehicle Fuel Containers and Their Installations," and in agreement with the manufacturer's recommendations. (76) Retarder: Device used to augment or replace some of the functions of primary friction based braking systems of the coach. (77) Rupture: Sudden and unstable damage propagation in the structural components of the container resulting in a loss of contents. See Leakage. (78) Seated Load: 150 lbs for every designed passenger seating position and for the driver. (79) SLW (Seated Load Weight): Curb weight plus seated load. (80) Serial Data Signals. A current loop based representation of ASCII or alphanumeric data used for transferring information between devices by transmitting a sequence of individual bits in a prearranged order of significance. (81) NOTE: An example is the communication that takes place between two or more electronic components with the ability to process and store information. (82) Service Pressure: The settled pressure at a uniform gas temperature of 21 °C (70 °F) and full gas content. It is the pressure for which the equipment has been constructed, under normal conditions. Also referred to as the nominal service pressure or working pressure. (83) Settled Pressure: The gas pressure when a given settled temperature, usually 21 °C (70 °F), is reached. (84) Settled Temperature: The uniform gas temperature after any change in temperature caused by filling has dissipated. (85) Solid State Alternator: A module that converts high-voltage DC to low -voltage DC (typically 12/24 V systems). (86) Sources of Ignition: Devices or equipment that because of their modes of use or operation, are capable of providing sufficient thermal energy to ignite flammable compressed natural gas -air mixtures when introduced into such a mixture, or when such a mixture comes into contact with them. (87) Special Tools: Tools not normally stocked by the Agency. (88) Specification: A particular or detailed statement, account or listing of the various elements, materials, dimensions, etc. involved in the manufacturing and construction of a product. (89) Standard: A firm guideline from a consensus group. Standards referenced in "Section 6: Technical Specifications" are the latest revisions unless otherwise stated. Section 5 — Page 15 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29113 (90) Standee Line: A line marked across the coach aisle to designate the forward area that passengers may not occupy when the coach is moving. (91) State of Charge (SOC): Quantity of electric energy remaining in the battery relative to the maximum rated amp -hour (Ah) capacity of the battery expressed in a percentage. This is a dynamic measurement used for the energy storage system. A full SOC indicates that the energy storage system cannot accept further charging from the engine -driven generator or the regenerative braking system. (92) Stress Loops: The "pigtails" commonly used to absorb flexing in piping. (93) Structure: The basic body, including floor deck material and installation, load-bearing external panels, structural components, axle mounting provisions and suspension beams and attachment points. (94) Thermally Activated Gas Relief Device: A relief device that is activated by high temperatures and generally contains a fusible material. (95) NOTE: Since this is a thermally activated device, it does not protect against over -pressure from improper charging practices. (96) Wheelchair: A mobility aid belonging to any class of three- or four -wheeled devices, usable indoors, designed for and used by individuals with mobility impairments, whether operated manually or powered. A "common wheelchair' is such a device that does not exceed 30 in. in width and 48 in. in length measured 2 in. above the ground, and does not weigh more than 600 lbs when occupied. TS -3 REFERENCED PUBLICATIONS The documents or portions thereof referenced within this specification shall be considered part of the requirements of the specification. The edition indicated for each referenced document is the current edition, as of the date of the APTA issuance of this specification. TS -4 LEGAL REQUIREMENTS The Contractor shall comply with all applicable federal, state and local regulations. These shall include but not be limited to ADA, as well as state and local accessibility, safety and security requirements. Local regulations are defined as those below the state level. Coaches shall meet all applicable FMVSS regulations and shall accommodate all applicable FMCSR regulations in effect at the location of the Agency and the date of manufacture. In the event of any conflict between the requirements of these specifications and any applicable legal requirement, the legal requirement shall prevail. Technical requirements that exceed the legal requirements are not considered to conflict. Section 5 — Page 16 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 TS -5 OVERALL REQUIREMENTS The Contractor shall ensure that the application and installation of major coach subcomponents and systems are compliant with all such subcomponent vendors' requirements and recommendations. Contractor and Agency shall identify subcomponent vendors that shall submit installation/application approval documents with the completion of the first CNG and Diesel coach. Components used in the vehicle shall be of heavy-duty design and proven in transit service. TS -5.1 WEIGHT It shall be a design goal to construct each coach as light in weight as possible without degradation of safety, appearance, comfort, traction or performance. Coaches at a capacity load shall not exceed the tire factor limits, brake test criteria or structural design criteria. TS -5.2 CAPACITY The vehicle shall be designed to carry the gross vehicle weight, which shall not exceed the coach GVWR. TS -5.3 SERVICE LIFE The minimum useful design life of the coach in transit service shall be at least twelve (12) years or 500,000 miles. It shall be capable of operating at least 40,000 miles per year, including the 12th year. TS -5.4 MAINTENANCE AND INSPECTION Scheduled maintenance tasks shall be related and shall be in accordance with the manufacturer's recommended preventative maintenance schedule (along with routine daily service performed during the fueling operations). Test ports, as required, shall be provided for commonly checked functions on the coach, such as air intake, exhaust, hydraulic, pneumatic, charge -air and engine cooling systems. The coach manufacturer shall give prime consideration to the routine problems of maintaining the vehicle. All coach components and systems, both mechanical and electrical, which will require periodic physical work or inspection processes shall be installed so that a minimum of time is consumed in gaining access to the critical repair areas. It shall not be necessary to disassemble portions of the coach structure and/or equipment such as seats and flooring under seats in order to gain access to these areas. Each coach shall be designed to facilitate the disassembly, reassembly, servicing or maintenance, using tools and equipment that are normally available as standard commercial items. Requirements for the use of unique specialized tools will be minimized. The body and structure of the coach shall be designed for ease of maintenance and repair. Individual panels or other equipment that may be damaged in normal service shall be repairable or replaceable. Ease of repair shall be related to the vulnerability of the item to damage in service. Section 5 — Page 17 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29,13 Contractor shall provide a list of all special tools and pricing required for maintaining this equipment. Said list shall be submitted as a supplement to the Pricing Schedule. NOTE: Tools such as compartment door keys, bellows gauges and other tools that are required for daily maintenance and inspections shall not be included in the special tool list and shall be furnished for each coach. TS -5.5 INTERCHANGEABILITY Unless otherwise agreed, all units and components procured under this Contract, whether provided by Suppliers or manufactured by the Contractor, shall be duplicates in design, manufacture and installation to ensure interchangeability among coaches in each order group in this procurement. This interchangeability shall extend to the individual components as well as to their locations in the coaches. These components shall include, but are not limited to, passenger window hardware, interior trim, lamps, lamp lenses and seat assemblies. Components with non -identical functions shall not be, or appear to be, interchangeable. Any one component or unit used in the construction of these coaches shall be an exact duplicate in design, manufacture and assembly for each coach in each order group in this Contract. Contractor shelf identify and secure approval for any changes in components or unit construction provided within a Contract. In the event that the Contractor is unable to comply with the interchangeability requirement, the Contractor must notify the Agency and obtain the Agency's prior written approval, including any changes in pricing. Agency shall review proposed product changes on a case-by-case basis and shall have the right to require extended warranties to ensure that product changes perform at least as well as the originally supplied products. TS -5.6 TRAINING Shall be provided by the proposer at the rate of 40 hours of instruction for each transit agency. Each agency will specify their individual needs with regard to training topics or subjects. Trainers will be available to train at each agencies perspective site at mutually agreed upon dates and times. The specified training must be completed within the 12 month period following the delivery of the first unit at each agency and may be started up to 90 days prior to the first delivery upon mutual agreement. The Contractor also shall provide visual and other teaching aids (such as manuals, slide presentations and literature) for use by the Agency's own training staff, which becomes the property of the Agency. TS -5.6.1 TECHNICAUSERVICE REPRESENTATIVES The Contractor shall, at its own expense, have one or more competent technical service representatives available on request to assist the Agency in the solution of engineering or design problems within the scope of the specifications that may arise during the warranty period. This does not relieve the Contractor of responsibilities under the provisions of "Section 7: Warranty Requirements." Section 5 — Page 18 VVTA Solicitation No, 2013-04 Rev 4 Dated 8/29/13 TS -5.7 OPERATING ENVIRONMENT The Coach shall achieve normal operation in ambient temperature ranges of 10 OF to 115 OF, at relative humidity between 5 percent and 100 percent, and at altitudes up to 3000 ft above sea level. Degradation of performance due to atmospheric conditions shall be minimized at temperatures below 10 OF, above 115 OF or at altitudes above 3000 ft. Altitude requirements above 3000 ft will need separate discussions with the engine manufacturer to ensure that performance requirements are not compromised. Speed, gradability and acceleration performance requirements shall be met at, or corrected to, 77 OF, 29.31 in. Hg, dry air per SAE J1995. TS -5.8 NOISE TS -5.8.1 INTERIOR NOISE The combination of inner and outer panels and any material used between them shall provide sufficient sound insulation so that a sound source with a level of 80 dBA measured at the outside skin of the coach shall have a sound level of 65 dBA or less at any point inside the coach. These conditions shall prevail with all openings, including doors and windows, closed and with the engine and accessories switched off. The coach -generated noise level experienced by a passenger at any seat location in the coach shall not exceed 80 dBA. The driver area shall not experience a noise level of more than 75 dBA. Measurements of interior noise levels shall be taken in accordance with ISO 3381. An exception shall be made for the turntable area, which shall be considered a separate environment. TS -5.8.2 EXTERIOR NOISE Airborne noise generated by the coach and measured from either side shall not exceed 80 dBA under full power acceleration when operated at 0 to 35 mph at curb weight. The maximum noise level generated by the coach pulling away from a stop at full power shall not exceed 83 dBA. The coach - generated noise at curb idle shall not exceed 65 dBA. If the noise contains an audible discrete frequency, a penalty of 5 dBA shall be added to the sound level measured. The Contractor shall comply with the exterior noise requirements defined in local laws and ordinances identified by the Agency and SAE J366. TS -5.9 FIRE SAFETY The coach shall be designed and manufactured in accordance with all applicable fire safety and smoke emission regulations. These provisions shall include the use of fire-retardant/low-smoke materials, fire detection systems, bulkheads and facilitation of passenger evacuation. TS -5.9.1 MATERIALS All materials used in the construction of the passenger compartment of the coach shall be in accordance with the Recommended Fire Safety Practices defined in FMVSS 302. Section 5 — Page 19 VVTA Solicitation No. 2013-04 Rev 4 Dated 829/13 TS -5.10 FIRE SUPPRESSION The coach shall have a fire suppression system installed per manufacturer's recommendations. TS -5.11 RESPECT FOR THE ENVIRONMENT In the design and manufacture of the coach, the Contractor shall make every effort to reduce the amount of potentially hazardous waste. In accordance with Section 6002 of the Resource Conservation and Recovery Act, the Contractor shall use, whenever possible and allowed by the specifications, recycled materials in the manufacture of the coach. TS -6 PHYSICAL SIZE With exceptions such as exterior mirrors, marker and signal lights, bumpers, fender skirts, washers, wipers, ad frames, cameras, object detection systems, bicycle racks, feelers and rub rails, the coach shall be close to the following overall dimensions as shown in Figure 1 at static conditions and design height. Contractor to provide drawings with dimensions of proposed coach. FIGURE 1 Transit Coach Exterior Dimensions IN L 1%3TH OVER SUTAPF.98 OODY EENG IH 00 iEA5' LN'. ANS FRONT OVERHANG Section 5 — Page 20 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 OVEPA A HEIC•HT w:77:,. WIDTH �r TS -6.1 COACH LENGTH For ease of use, the following tolerances will be allowable for each given coach length. Coach length is determined as the measurement from bumper to bumper. • 45 ft coach: 45 to 47 R TS -6.2 COACH WIDTH 102 in. Width Coach Body. Width shall be 102 in. (+0, -1 in.). TS -6.3 COACH HEIGHT Maximum Overall Height: Maximum overall height shall be 140 in., including all rigid, roof -mounted items such as A/C, exhaust, fuel system and cover, etc. TS -6.4.1 STEP HEIGHT The step height shall not exceed 16.5 in. at doorway without kneeling and shall not exceed 15.5 in. at the step. TS -6.5 UNDERBODY CLEARANCE The coach shall maintain the minimum clearance dimensions as defined and shown in Figure 2 of SAE Standard J689, regardless of load up to the gross vehicle weight rating. TS -6.6 RAMP CLEARANCES The approach angle is the angle measured between a line tangent to the front tire static loaded radius arc and the initial point of structural interference forward of the front tire to the ground. The departure angle is the angle measured between a line tangent to the rear tire static loaded radius arc and the initial point of structural interference rearward of the rear tire to the ground. Section 5 — Page 21 VVTA Solicitation No 2013-04 Rev 4 Dated 8/29/13 The breakover angle is the angle measured between two lines tangent to the front and rear tire static loaded radius and intersecting at a point on the underside of the vehicle that defines the largest ramp over which the vehicle can roll. TABLE 2 Default Breakover Angle Angle 45 ft Coach Approach 8.6 deg (min.) Front break over 8 deg (min.) Departure 8.6 deg (min.) TS -6.7 GROUND CLEARANCE Ground clearance shall be no less than 9 in., (8 in. at jacking pad) except within the axle zone and wheel area. Axle zone clearance, which is the projected area between tires and wheels on the same axial centerline, shall be no less than 5.4 in. Wheel area clearance shall be no less than 8 in. for parts fixed to the coach body and 6 in. for parts that move vertically with the axles. — FIGURE 2 Transit Coach Minimum Road Clearance Ir WHEEL WHEEL AREA_ �`- I � AXL \ AXLE, T .,* Section 5 — Page 22 VVI A Solicitation No. 2013-04 Rev 4 Dated B/29/13 REAR I� Nh WHEEL BASE -I FRONT I I I ANGLE ANGLE TS -6.8 FLOOR HEIGHT APPROACH 7 ANGLE Height of the step above the street shall be no more than 16 in. measured at the centerline of the doorway. All Floor measurements shall be with the coach at the design running height and on a level surface and with the standard installed tires. TS -6.9 INTERIOR HEADROOM Headroom above the aisle and at the centerline of the aisle seats shall be no less than 78 in. in the forward half of the coach tapering to no less than 74 in. forward of the rear settee. At the centerline of the window seats, headroom shall be no lower than 65 in., except for parcel racks and reading lights, if specified. Headroom at the back of the rear bench seat may be reduced to a minimum of 56 in., but it shall increase to the ceiling height at the front of the seat cushion. In any area of the coach directly over the head of a seated passenger and positioned where a passenger entering or leaving the seat is prone to strike his or her head, padding shall be provided on the overhead paneling. VEHICLE PERFORMANCE TS -7 POWER REQUIREMENTS The propulsion system shall be sized to provide sufficient power to enable the coach to meet the defined acceleration, top speed and gradability requirements, and operate all propulsion -driven accessories using actual road test results and computerized vehicle performance data. Proposer to provide horse power and torques specifications along with transmission and axle gear ratios. TS 7.1 TOP SPEED The coach shall be capable of achieving a top speed of 70 mph on a straight, level road at GVWR with all accessories operating. The coach shall be capable of safely maintaining the vehicle speed according to the recommendations by the tire manufacturer. NOTE: Values are assumed to be sustained. Manufacturer shall supply Agency with data if there is a variance between peak performance and sustained vehicle performance. Section 5 — Page 23 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS 7.2 GRADABILITY Gradability requirements shall be met on grades with a dry commercial asphalt or concrete pavement at GVWR with all accessories operating. The propulsion system shall enable the coach to achieve and maintain a speed of 40 mph on a 2'/2 percent ascending grade and 15 mph on a 10 percent ascending grade continuous. NOTE: Values are assumed to be sustained. Manufacturer shall supply Agency with data if there is a variance between peak performance and sustained vehicle performance. TS 7.2.1 ACCELERATION TS 7.2.2 NON -HYBRID The acceleration shall meet the requirements in Table 3 below and shall be sufficiently gradual and smooth to prevent throwing standing passengers off-balance. Acceleration measurement shall commence when the accelerator is depressed. TABLE 3 Maximum Start Acceleration Times on a Level Surface' Speed (mph) Maximum time (seconds) 10 5 20 10 30 18 40 30 50 60 Top speed 1. Vehicle weight = GVVVR The Contractor shall provide performance scans to the Agency based on the Agency's specific drivetrain configuration. TS 7.3 OPERATING RANGE The operating range of the coach shall be designed to meet the operating profile as stated in the "Design Operating Profile" section. The diesel coach shall have a minimum operating range of 400 miles on a full tank of fuel. Section 5 — Page 24 VVTA Solicitation No. 2013-04 Rev 4 Dated QW13 TS 7.3.2 CNG The operating range of the CNG coach shall be at least 400 miles with an initial gas -settled pressure of 3600 psi at 70 OF. TS -8 FUEL ECONOMY (DESIGN OPERATING PROFILE) Test results from the FTA ABD Cycle economy tests or other applicable test procedures shall be provided to the Agency. Results shall include vehicle configuration and test environment information. Fuel economy data shall be provided for each design operating profile. The design operating profile is assumed to be defined by the FTA ABD Cycle. Fuel economy tests shall be run on these four duty cycles: - Manhattan: 6.8 mph - Orange County: 12.7 mph - UDDS: 19 mph - Idle time POWERPLANT TS -9 ENGINE The engine shall comply with applicable local, state and/or federal emissions and useful life requirements. The engine shall have a design life of not less than 300,000 miles without replacement or major service. The lifetime estimate is based on the design operating profile. NOTE: For CNG engines a minimum rating horsepower of 320 and minimum torque rating of 1000 ft. - lbs. shall be installed and a higher horsepower and torque rating is preferred if available. For Diesel engines a minimum rating horsepower of 400 and minimum torque rating of 1400 ft.-Ibs. shall be installed. The engine shall be equipped with an electronically controlled management system, compatible with either 12 or 24 V power distribution. The engine control system shall be capable of transmitting and receiving electronic inputs and data from other drivetrain components and broadcasting that data to other vehicle systems. Communication between electronic drivetrain components and other vehicle systems shall be made using the communications networks. The engine's electronic management system shall monitor operating conditions and provide instantaneous adjustments to optimize both engine and coach performance. The system shall be programmable to allow optimization of programmable features. The engine starting system shall be protected by an interlock that prevents its engagement when the engine is running. Special equipment or procedures may be employed to start the coach when exposed Section 5 — Page 25 VVTA Solicitation No, 2013-1M Rev 4 Dated 829/13 to temperatures less than 30 OF for a minimum of four hours without the engine in operation. All cold weather starting aids, engine heating devices and procedures shall be of the type recommended by the engine manufacturer and approved by the Agency. The integration of all systems on the vehicle relative to engine idle speed shall be the responsibility of the vehicle manufacturer to meet the requirements of the transit property. The engine control system shall protect the engine against progressive damage. The system shall monitor conditions critical for safe operation and automatically derate power and/or speed and initiate engine shutdown as needed. Automatic Engine Protection/Shutdown Override Feature: A control shall be available to the operator/driver that when constantly depressed and released will delay the engine shutdown or allow the coach to be moved. Override action shall be recorded. This data shall be retrievable by the Agency. TS 9.1 ENGINE (CNG) The engine shall meet all regulatory requirements when operating on fuel equal to CARB Specifications for Compressed Natural Gas #2292.5. The four predominant characteristics that must be met are methane, ethane, butane and propane. TS -10 COOLING SYSTEMS The cooling systems shall be of sufficient size to maintain all engine and transmission fluids and engine intake air at safe, continuous operating temperatures during the most severe operations possible and in accordance with engine and transmission manufacturers' cooling system requirements. The cooling system fan controls should sense the temperatures of the operating fluids and the intake air, and if either is above safe operating conditions, the cooling fan should be engaged. The fan control system shall be designed with a fail-safe mode of "fan on." The cooling system shall meet the requirements stated in the operating environment. TS 10.1 ENGINE COOLING A means of determining satisfactory engine coolant level shall be provided. A spring-loaded, push- button type valve or lever shall be provided to safely release pressure or vacuum in the cooling system with both it and the water filler no more than ±60 in. above the ground. Both shall be accessible through the same access door. The cooling fan shall be temperature controlled, allowing the engine to reach operating temperature quickly. TS 10.1.1 COOLANT The engine cooling system shall be equipped with a properly sized water filter with a spin -on element and an automatic system for releasing supplemental coolant additives as needed to replenish and maintain protection properties. When replacing the water filter, only the water in the filter will be lost. Section 5 — Page 26 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS 10.1.2 DRIVE DESIGN The coach shall be equipped with an electric fan drive coach cooling system. A screen guard must be installed on electric motor fans per SAE A 308. TS 10.1.3 MOUNTING Mounting location of radiator and charge air cooler shall be the Contractor's standard design. TS 10.2 TRANSMISSION COOLING The transmission shall be cooled by a dedicated heat exchanger sized to maintain operating fluid within the transmission manufacturer's recommended parameters of flow, pressure and temperature. The transmission cooling system shall be matched to the retarder and engine cooling systems to ensure that all operating fluids remain within recommended temperature limits established by each component manufacturer. The engine cooling system should provide coolant bypass flow to the transmission cooling system with the engine thermostats closed. Unless otherwise noted, the transmission cooler is to be the first component to see cold water from the radiator outlet. In addition, all return water piping, aside from the thermostat bypass line, is to be plumbed in after the transmission cooler. TS -11 TRANSMISSION (CONVENTIONAL POWERTRAIN) The transmission shall be multiple speed, automatic shift with torque converter, retarder and electronic controls. Gross input power, gross input torque and rated input speed shall be compatible with the engine. The transmission shall be designed to operate for not less than 300,000 miles on the design operating profile without replacement or major service. The transmission should be easily removable without disturbing the engine and accessible for service. The electronic controls shall be capable of transmitting and receiving electronic inputs and data from other drivetrain components and of broadcasting that data to other vehicle systems. Communication between electronic drivetrain components and other vehicle systems shall be made using the communications networks. Electronic controls shall be compatible with either 12 or 24 V power distribution, provide consistent shift quality, and compensate for changing conditions, such as variations in vehicle weight and engine power. At a minimum, drivetrain components consisting of the engine, transmission, retarder, ASR, and anti-lock braking systems shall be powered by a dedicated and isolated ignition supply voltage to ensure data communication among components exists when the vehicle ignition is switched to the "on" position. A nominal brake pedal application of 15 to 20 psi shall be required by the driver to engage forward or reverse range from the neutral position to prevent sudden acceleration of the coach from a parked position. The electronically controlled transmission shall have on -board diagnostic capabilities, be able to monitor functions, store and time -stamp out -of -parameter conditions in memory, and communicate faults and vital conditions to service personnel. The transmission shall contain built-in protection software to guard Section 5 — Page 27 V VTA Solicitation No. 2013-04 Rev 4 Dated 829/13 against severe damage. The on -board diagnostic system shall trigger a visual alarm to the driver when the electronic control unit detects a malfunction. An electronic transmission fluid level monitoring and protection system shall be provided. TS -12 RETARDER (CNG) The powertrain shall be equipped with a retarder designed to extend brake lining service life. The application of the retarder shall cause a smooth blending of both retarder and service brake function and shall not activate the brake lights Actuation of ABS and/or automatic traction control (ATC) shall override the operation of the brake retarder. The retarder shall be adjustable within the limits of the powertrain and activated when the brake pedal is depressed. The Agency will work with the OEM/drive system manufacturer to determine retarder performance settings. The retarder disable switch shall be accessible to the seated driver TS -13 ENGINE BRAKE (DIESEL) The powertrain shall be equipped with an engine brake designed to extend brake lining service life. The application of the engine brake shall cause a smooth blending of both engine brake and service brake function and shall not activate the brake lights The retarder disable switch shall be accessible to the seated driver. TS -14 MOUNTING All powerplant mounting shall be mechanically isolated to minimize transfer of vibration to the body structure and provide a minimum clearance of 0.75 in. Mounts shall control the movement of the powerplant so as not to affect performance of belt -driven accessories or cause strain in piping and wiring connections to the powerplant. TS 14.1 SERVICE The propulsion system shall be arranged for ease of access and maintenance. The Contractor shall list all special tools, fixtures or facility requirements recommended for servicing. The muffler, exhaust system, air cleaner, air compressor, starter, alternator, radiator, all accessories and any other component requiring service or replacement shall be easily removable and independent of the engine and transmission removal. An engine oil pressure gauge and coolant temperature gauge shall be provided in the engine compartment. These gauges shall be easily read during service and mounted in an area where they shall not be damaged during minor or major repairs. An air cleaner with a dry filter element and a graduated air filter restriction indicator shall be provided. The location of the air intake system shall be designed to minimize the entry of dust and debris and to Section 5 — Page 28 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 maximize the life of the air filter. The engine air duct shall be designed to minimize the entry of water into the air intake system. Drainage provisions shall be included to allow any water/moisture to drain prior to entry into the air filter. All fluid fill locations shall be properly labeled to help ensure that correct fluid is added. All fillers shall be easily accessible with standard funnels, pour spouts and automatic dispensing equipment TS -15 HYDRAULIC SYSTEMS Hydraulic system service tasks shall be minimized and scheduled no more frequently than those of other major coach systems. All elements of the hydraulic system shall be easily accessible for service or unit replacement. Critical points in the hydraulic system shall be fitted with service ports so that portable diagnostic equipment may be connected or sensors for an off -board diagnostic system permanently attached to monitor system operation when applicable. A tamper -proof priority system shall prevent the loss of power steering during operation of the coach if other devices are also powered by the hydraulic system. The hydraulic system shall operate within the allowable temperature range as specified by the lubricant manufacturer. TS 15.1 FLUID LINES All lines shall be rigidly supported to prevent chafing damage, Fatigue Failures, degradation and tension strain. Lines should be sufficiently flexible to minimize mechanical loads on the components. Lines passing through a panel, frame or bulkhead shall be protected by grommets (or similar devices) that fit snugly to both the line and the perimeter of the hole that the line passes through to prevent chafing and wear. Pipes and fluid hoses shall not be bundled with or used to support electrical wire harnesses. Lines shall be as short as practicable and shall be routed or shielded so that failure of a line shall not allow the contents to spray or drain onto any component operable above the auto -ignition temperature of the fluid. All hoses, pipes, lines and fittings shall be specified and installed per the manufacturer's recommendations. TS 15.2 FITTINGS AND CLAMPS All clamps shall maintain a constant tension at all times, expanding and contracting with the line in response to temperature changes and aging of the line material. The lines shall be designed for use in the environment where they are installed (for example, high-temperature resistant in the engine compartment, resistant to road salts near the road surface, and so on). Compression fittings shall be standardized to prevent the intermixing of components. Compression fitting components from more than one manufacturer shall not be mixed, even if the components are known to be interchangeable. Section 5 — Page 29 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS 15.3 CHARGE AIR PIPING Charge air piping and fittings shall be designed to minimize air restrictions and leaks. Piping shall be as short as possible, and the number of bends shall be minimized. Bend radii shall be maximized to meet the pressure drop and temperature rise requirements of the engine manufacturer. The cross section of all charge air piping shall not be less than the cross section of the intake manifold inlet. Any changes in pipe diameter shall be gradual to ensure a smooth passage of air and to minimize restrictions. Piping shall be routed away from heat sources as practicable and shielded as required to meet the temperature rise requirements of the engine manufacturer. Charge air piping shall be constructed of stainless steel, aluminized steel, anodized aluminum or painted steel rated at minimum 1000 hours of salt spray according to ASTM B117, except between the air filter and turbocharger inlet, where piping may be constructed of flexible heat -resistant material. Connections between all charge air piping sections shall be sealed with a short section of reinforced hose and secured with stainless steel constant tension clamps that provide a complete 360 deg seal. TS -16 RADIATOR Radiator piping shall be stainless steel, brass tubing or painted steel rated at 1000 hours of salt spray according to ASTM 8117 and where practicable, hoses shall be eliminated, including biodiesel. Necessary hoses shall be impervious to all coach fluids. All hoses shall be secured with stainless steel clamps that provide a complete 360 deg seal. The clamps shall maintain a constant tension at all times, expanding and contracting with the hose in response to temperature changes and aging of the hose material. TS -17 OIL AND HYDRAULIC LINES Oil and hydraulic lines shall be compatible with the substances they carry. The lines shall be designed and intended for use in the environment where they are installed (for example, high-temperature resistant in the engine compartment, resistant to road salts near the road surface and so on). Lines within the engine compartment shall be composed of steel tubing where practicable, except in locations where flexible lines are required. Hydraulic lines of the same size and with the same fittings as those on other piping systems of the coach, but not interchangeable, shall be tagged or marked for use on the hydraulic system only. TS -18 FUEL TS 18.1 FUEL LINES Fuel lines shall be securely mounted, braced and supported as designed by the coach manufacturer to minimize vibration and chafing and shall be protected against damage, corrosion or breakage due to strain or wear. Section 5 — Page 30 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 Manifolds connecting fuel containers shall be designed and fabricated to minimize vibration and shall be installed in protected locations to prevent line or manifold damage from unsecured objects or road debris. Fuel hose and hose connections, where permitted, shall be made from materials resistant to corrosion and fuel and protected from fretting and high heat. Fuel hoses shall be accessible for ease of serviceability. TS 18.1.1 FUEL LINES, DIESEL Fuel lines shall be capable of carrying the type of fuel the engine manufacturer recommends. TS 18.1.2 FUEL LINES, CNG Fuel lines shall comply with NFPA-52. All tubing shall be a minimum of seamless Type 304 stainless steel (ASTM A269 or equivalent). Fuel lines and fittings shall not be fabricated from cast iron, galvanized pipe, aluminum, plastic or copper alloy with content exceeding 70 percent copper. Pipe fittings and hoses shall be clear and free from cuttings, burrs or scale. Pipe thread joining material that is impervious to CNG shall be utilized as required. Fuel lines shall be identifiable as fuel lines only. High-pressure CNG lines shall be pressure tested to a minimum of 125 percent of system working pressure prior to fueling. CNG, nitrogen or clean, dry air shall be used to pressure -test the lines/assembly. The coach manufacturer shall have a documented procedure for testing the high- pressure line assembly. Fuel lines shall be securely mounted, braced and supported using "split -block" type or stainless steel P clamps; all mounting clamps shall be mounted to a rigid structure to minimize vibration and shall be protected against damage, corrosion or breakage due to strain, rubbing or wear. "Floating clamps" (not mounted to a rigid structure) shall not be permitted. Fuel lines shall not be used to secure other components (wires, air lines, etc.). Manifolds connecting fuel containers shall be designed and fabricated to minimize vibration and shall be installed in protected location(s) to prevent line or manifold damage from unsecured objects or road debris. Fuel hose connections, where permitted, shall be less than 48 in. in length, made from materials resistant to corrosion and action of natural gas, and protected from fretting and high heat and shall be supported approximately every 12 in. DESIGN AND CONSTRUCTION Section 5 — Page 31 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13. TS 18.2 DESIGN AND CONSTRUCTION TS 18.2.1 DIESEL FUEL TANK(S) The fuel tank(s) shall be securely mounted to the coach to prevent movement during coach maneuvers and be the standard design of the coach manufacturer. Contractor to supply specifics on proposed fuel tanks. The fuel tank(s) shall be equipped with an external, hex head, drain plug. It shall be at least a % in. size and shall be located at the lowest point of the tank(s). The fuel tank(s) shall have an inspection plate or easily removable filler neck to permit cleaning and inspection of the tank(s) without removal from the coach. The tank(s) shall be baffled internally to prevent fuel -sloshing regardless of fill level. The baffles or fuel pickup location shall assure continuous full power operation on a 6 percent upgrade for 15 minutes starting with no more than 25 gal of fuel over the unusable amount in the tank(s).The coach shall operate at idle on a 6 percent downgrade for 30 minutes starting with no more than 10 gal of fuel over the unusable amount in the tank(s). The materials used in mounting shall withstand the adverse effects of road salts, fuel oils and accumulation of ice and snow for the life of the coach. Labeling The capacity, date of manufacture, manufacturer name, location of manufacture, and certification of compliance to federal motor carrier safety regulations shall be permanently marked on the fuel tank(s).The markings shall be readily visible and shall not be covered with an undercoating material. Fuel Filler The fuel filler shall be located 7 to 32 ft behind the centerline of the front door on the curbside of the coach. The filler cap shall be retained to prevent loss and shall be recessed into the body so that spilled fuel will not run onto the outside surface of the coach. The fuel lines forward of the engine bulkhead shall be in conformance to SAE Standards. TS 18.2.2 DESIGN AND CONSTRUCTION, CNG Fuel Containers/Cylinders CNG fuel containers/cylinders must be designed, constructed, manufactured and tested in accordance with the following: NFPA 52 -Standard for Compressed Natural Gas (CNG) Vehicular Fuel Systems FMVSS 304 Any local standard(s) specifically intended for CNG fuel containers The design and construction of the fuel system supplied by the OEM shall comply with federal, state, and local regulations. Section 5 — Page 32 V VTA Solicitation No. 2013-04 Rev 4 Dated W9113 Installation Fuel cylinders shall be installed in accordance with ANSI/IAS NGV2 - 1998, "Basic Requirements for Compressed Natural Gas Vehicles (NGV) Fuel Containers" and NFPA 52, "Compressed Natural Gas (CNG) Vehicular Fuel Systems Code," 1998 edition, Section 303. Fuel cylinders, attached valves, pressure relief devices, and mounting brackets should be installed and protected so that their operation is not affected by coach washers and environmental agents such as rain, snow, ice or mud. These components should be protected from significant damage caused by road debris or collision. The roof and area above the engine mounted tanks shall be contained within a skeletal structure resembling a roll cage and contained within an enclosure. The enclosure shall incorporate a hinged clamshell type access. The access panels shall be designed to offer protection from weather and to be sacrificial as a means of providing an escape path to atmosphere upon rapid enclosure pressure rise. The latching method shall utilize quick -release captive hardware that can be demonstrated to last the life of the coach. Additional shielding shall be provided surrounding end fittings and valves as needed. Shields shall be attached to the coach structure hinged in a manner that permits one mechanic to unlatch and swing the shield open for routine inspections. As practical, electrical components shall not be located within the roof enclosure, and if unavoidable, they shall be intrinsically safe. CNG fueled coaches shall be equipped with an active automatic gas detection system, which shall annunciate unsafe levels of methane. The automatic gas detection system shall be integrated with an onboard fire suppression system. Labeling CNG fuel systems shall be labeled in accordance with NFPA 52, "Compressed Natural Gas (CNG) Vehicular Fuel Systems Code," 1998 edition and all current federal, state, and local regulations. Pressure Relief Devices (PRDs) PRDs must be designed, constructed, manufactured and tested in accordance with ANIS/IAS PRD1 - 1998, 'Pressure Relief Devices for Natural Gas Vehicle (NGV) Fuel Containers" and ANSI/IAS NGV2- 1998, "Basic Requirements for Compressed Natural Gas Vehicle (NGV) Fuel Containers." All natural gas fuel system piping, including the PRD vent line, shall be stainless steel. All PRDs must be vented to outside. Valves Valves must be installed in accordance with ANIS/IAS NGV2 - 1998, "Basic Requirements for Compressed Natural Gas Vehicle (NGV) Fuel Containers" and NFPA 52, "Standard for Compressed Natural Gas (CNG) Vehicular Fuel Systems." Fuel Filler Section 5 — Page 33 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 The fuel filler shall be located on the curb side 7 to 38 ft. to the rear of the passenger door opening. The filler cap shall be retained to prevent loss and shall be recessed into the body. The fill and vent receptacles shall be located within an enclosure on the right side of the coach. The access door shall be sized to allow full viewing of gauges, ease of hookups and maneuver of fuel nozzle. The fuel fill receptacle and vent receptacle attachment shall be robust and capable of routine fueling connects/disconnects without deflection or metal fatigue, and capable of withstanding mechanical loads induced by a fueling drive -away incident without attachment failure. Fueling System The CNG fueling port receptacle shall be an ANSI/AGA NGV1 or NGV2 certified receptacle as designated by the Agency. The coach shall be capable of being fueled by a nozzle determined by the Agency. The fueling port receptacle location shall be such that connection by fueling personnel can be performed without physical strain or interference. A dust cap shall be permanently "tethered" to the fueling port receptacle. The fueling port receptacle access door shall be equipped with an interlock sensor that disables the engine starting system and/or fuel system so when the access door is open the engine will not start or run, to prevent drive-aways. The interlock shall be of the type such that if the sensor fails, the coach will not start. Fueling site characteristics such as pressure, Flow rate and temperature shall be provided by the Agency if requested. Defueling System The CNG defueling port shall be an NGV-3.1/CGA-12.3 certified receptacle. The CNG defueling port shall be located on the curbside of the coach, in a location that is compatible with the Agency's defueling station operation. The defueling system shall incorporate the following characteristics: • Dust cap permanently "tethered" to the defueling port. • Device(s) to prevent inadvertent defueling. Specifications to be provided by Agency. • Components compatible with Agency's defueling operation. • The piping and fittings onboard the coach shall be sized to allow the fueling station to meet the following operating parameters: TS -19 EMISSIONS AND EXHAUST TS 19.1 EXHAUST EMISSIONS The engine and related systems shall meet all applicable emission and engine design guidelines and standards. Section 5 — Page 34 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29113 1�lkf%�WTS_ ,F3C1VJ&1f:4t'1 The exhaust pipe shall be of sufficient height to prevent exhaust gases and waste heat from discoloring or causing heat deformation to the coach. The entire exhaust system shall be adequately shielded to prevent heat damage to any coach component, including the exhaust after -treatment compartment area. The exhaust outlet shall be designed to minimize rain, snow or water generated from high-pressure washing systems from entering into the exhaust pipe and causing damage to the after -treatment. Exhaust gases and waste heat shall be discharged from the roadside rear corner of the roof or rear bumper. TS 19.3 EXHAUST AFTER -TREATMENT An exhaust after -treatment system will be provided to ensure compliance to all applicable EPA regulations in effect if required. Diesel Exhaust Fluid Injection If required by the engine manufacturer to meet NOx level requirements specified by EPA, a DEF injection system will be provided. The DEF system will minimally include a tank, an injector, a pump, an ECM and a selective catalytic converter. The tanks shall be designed to store DEF in the operating environment described in the "Operating Environment' section. TS 19.4 PARTICULATE AFTER -TREATMENT (DIESEL) If required by the engine manufacturer to meet particulate level requirements specified by EPA, a particulate trap will be provided. The particulate trap shall regenerate itself automatically if it senses clogging. Regeneration cycles and conditions will be defined by the engine manufacturer. STRUCTURE TS -20 GENERAL TS 20.1 DESIGN The structure of the coach shall be designed to withstand the commuter road service conditions typical of an over the road coach duty cycle throughout its service life. The vehicle structural frame shall be designed to operate with minimal maintenance throughout the 12 -year design operating profile. The design operating profile specified by the Agency shall be considered for this purpose. TS -21 ALTOONA TESTING Prior to acceptance of first coach, the vehicle must have completed any FTA -required Altoona testing. Any items that required repeated repairs or replacement must undergo the corrective action with Section 5 — Page 35 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29113 supporting test and analysis. A report clearly describing and explaining the failures and corrective actions taken to ensure that any and all such failures will not occur shall be submitted to the Agency. If available, the Altoona Test Report shall be provided to the Agency with the Proposal submittal. If not available, then the report shall be provided prior to first acceptance of coach. TS 21.1 STRUCTURAL VALIDATION The structure of the coach shall have undergone appropriate structural testing and/or analysis. At minimum, appropriate structural testing and analysis shall include Altoona testing or finite element analysis (FEA). TS -22 DISTORTION The coach, loaded to GVWR and under static conditions, shall not exhibit deflection or deformation that impairs the operation of the steering mechanism, doors, windows, passenger escape mechanisms or service doors. Static conditions shall include the vehicle at rest with any one wheel or dual set of wheels on a 6 in. curb or in a 6 in. deep hole. TS -23 RESONANCE AND VIBRATION All structure, body and panel -bending mode frequencies, including vertical, lateral and torsional modes, shall be sufficiently removed from all primary excitation frequencies to minimize audible, visible or sensible resonant vibrations during normal service. TS 23.1 ENGINE COMPARTMENT BULKHEADS The passenger and engine compartment shall be separated by fire-resistant bulkheads. The engine compartment shall include areas where the engine and exhaust system are housed. This bulkhead shall preclude or retard propagation of an engine compartment fire into the passenger compartment and shall be in accordance with the Recommended Fire Safety Practices defined in FTA Docket 90A, dated October 20, 1993. Only necessary openings shall be allowed in the bulkhead, and these shall be fire- resistant. Any passageways for the climate control system air shall be separated from the engine compartment by fire-resistant material. Piping through the bulkhead shall have fire-resistant fittings sealed at the bulkhead. Wiring may pass through the bulkhead only if connectors or other means are provided to prevent or retard fire propagation through the bulkhead. Engine access panels in the bulkhead shall be fabricated of fire-resistant material and secured with fire-resistant fasteners. These panels, their fasteners and the bulkhead shall be constructed and reinforced to minimize warping of the panels during a fire that will compromise the integrity of the bulkhead. TS 23.2 CRASHWORTHINESS The coach body and roof structure shall withstand a static load equal to 150 percent of the curb weight evenly distributed on the roof with no more than a 6 in. reduction in any interior dimension. Windows shall remain in place and shall not open under such a load. These requirements must be met without the roof -mounted equipment installed. Section 5 — Page 36 V VTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 The coach shall withstand a 25 mph impact by a 4000 Ib automobile at any side, excluding doorways, along either side of the coach and the articulated joint, if applicable, with no more than 3 in. of permanent structural deformation at seated passenger hip height. This impact shall not result in sharp edges or protrusions in the coach interior. Exterior panels below 35 in. from ground level shall withstand a static load of 2000 lbs applied perpendicular to the coach by a pad no larger than 5 sq in. This load shall not result in deformation that prevents installation of new exterior panels to restore the original appearance of the coach. TS -24 CORROSION The coach flooring, sides, roof, understructure and axle suspension components shall be designed to resist corrosion or deterioration from atmospheric conditions and de-icing materials for a period of 12 years or 500,000 miles, whichever comes first. It shall maintain structural integrity and nearly maintain original appearance throughout its service life, with the Agency's use of proper cleaning and neutralizing agents. All materials that are not inherently corrosion resistant shall be protected with corrosion -resistant coatings. All joints and connections of dissimilar metals shall be corrosion resistant and shall be protected from galvanic corrosion. Representative samples of all materials and connections shall withstand a two-week (336 -hour) salt spray test in accordance with ASTM Procedure B-117 with no structural detrimental effects to normally visible surfaces and no weight loss of over 1 percent. TS -25 TOWING Each towing device shall withstand, without permanent deformation, tension loads up to 1.2 times the curb weight of the coach within 20 deg of the longitudinal axis of the coach. If applicable, the rear towing device(s) shall not provide a toehold for unauthorized riders. The method of attaching the towing device shall not require the removal, or disconnection, of front suspension or steering components. Removal of the bike rack is permitted for attachment of towing devices. Shop air connectors shall be provided at the front and rear of the coach and shall be capable of supplying all pneumatic systems of the coach with externally sourced compressed air. The location of these shop air connectors shall facilitate towing operations. Two rear recovery devices/tie downs shall permit lifting and towing of the coach for a short distance, such as in cases of an emergency, to allow access to provisions for front towing of coach. The method of attaching the tow bar or adapter shall require the specific approval of the Agency. Any tow bar or adapter exceeding 50 lbs should have means to maneuver or allow for ease of use and application. Each towing device shall accommodate a crane hook with a 1 in. throat. TS -26 JACKING It shall be possible to safely jack up the coach, at curb weight, with a common 10 -ton Floor jack with or without special adapter, when a tire or dual set is completely flat and the coach is on a level, hard surface, without crawling under any portion of the coach. Jacking from a single point shall permit raising Section 5 — Page 37 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 the coach sufficiently high to remove and reinstall a wheel and tire assembly. Jacking pads located on the axle or suspension near the wheels shall permit easy and safe jacking with the flat tire or dual set on a 6 in. high run-up block not wider than a single tire. The coach shall withstand such jacking at any one or any combination of wheel locations without permanent deformation or damage. Jacking pads shall be painted safety yellow and jacking points shall have decals applied identifying their location. TS -27 HOISTING The coach axles or jacking plates shall accommodate the lifting pads of a three -post hoist system. Jacking plates, if used as hoisting pads, shall be designed to prevent the coach from falling off the hoist. Other pads or the coach structure shall support the coach on jack stands independent of the hoist. The vehicle shall be capable of lifting by the wheels, and, as necessary to meet tire load requirements, the proper number for wheel lifts and/or adapters must be used. TS -28 FLOOR TS 28.1 DESIGN The floor shall be essentially a continuous plane, except at the wheel housings and platforms. Where the floor meets the walls of the coach, as well as other vertical surfaces such as platform risers, the surface edges shall be blended with a circular section of radius not less than 1/4 in. or installed in a fully sealed butt joint. Similarly, a molding or cover shall prevent debris accumulation between the floor and wheel housings. The vehicle floor in the area of the entrance and exit doors shall have a lateral slope not exceeding 2 deg to allow for drainage. The aisle of the coach shall be a sloped floor design and shall not exceed 5.5 deg off the horizontal or include one step not to exceed entrance door step heights. The floor shall be a continuous plane over the wheel housings. Where the floor meets the walls of the coach, as well as other vertical surfaces such as platform risers, the surface edges shall be blended with a circular section of radius not less than Y< in. or installed in a fully sealed butt joint. TS 28.2 CONSTRUCTION The floor shall consist of the subfloor and the floor covering that will last the life of the coach. The floor as assembled, including the sealer, attachments and covering, shall be waterproof, non -hygroscopic and resistant to mold growth. The subfloor shall be resistant to the effects of moisture, including decay (dry rot). It shall be impervious to wood -destroying insects such as termites. The floor deck may not be integral with the basic structure but shall be mounted on the structure securely to prevent chafing or horizontal movement. Sheet metal screws shall not be used to retain the floor. All floor fasteners shall he secured and protected from corrosion for the service life of the coach. The floor deck shall be reinforced as needed to support passenger loads. At GVWR, the floor shall have an elastic defection of no more than 0.375 in. (10 mm) from the normal plane. The floor shall withstand the application of 3.0 times gross load weight without permanent detrimental deformation. Section 5 — Page 38 VVTA Solicitation No. 2013-04 Rev _A_Dated 8/29/13 TS -29 PLATFORMS TS 29.1 DRIVER'S AREA The covering of platform surfaces and risers, except where otherwise indicated, shall be the same material as specified for floor covering. Trim shall be provided along top edges of platforms unless integral nosing is provided. Specific trim required to be specified by each individual Agency. TS 29.2 FAREBOX Farebox placement should minimize impact to passenger access and minimize interference with the driver's line of sight. If the driver's platform is higher than 12 in., then the farebox is to be mounted on a platform of suitable height to provide accessibility for the driver without compromising passengers' access. TS -30 WHEEL HOUSING TS 30.1 DESIGN AND CONSTRUCTION Sufficient clearance and air circulation shall be provided around the tires, wheels and brakes to preclude overheating when the coach is operating on the design operating profile. Wheel housings shall be constructed of corrosion -resistant and fire-resistant material. Wheel housings, as installed and trimmed, shall withstand impacts of a 2 in. steel ball with at least 200 ft -lbs of energy without penetration. CHASSIS TS -31 SUSPENSION TS 31.1 GENERAL REQUIREMENTS The front, rear and mid (if articulated) suspensions shall be pneumatic type. The basic suspension system shall last the service life of the coach without major overhaul or replacement. Adjustment points shall be minimized and shall not be subject to a loss of adjustment in service. Routine adjustments shall be easily accomplished by limiting the removal or disconnecting the components. TS 31.2 ALIGNMENT All axles should be properly aligned so the vehicle tracks accurately within the size and geometry of the vehicle. Section 5 — Page 39 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29113 TS 31.3 SPRINGS AND SHOCK ABSORBERS TS 31.3.1 SUSPENSION TRAVEL The suspension system shall permit a minimum wheel travel of 2.75 in. jounce -upward travel of a wheel when the coach hits a bump (higher than street surface), and 2.75 in. rebound -downward travel when the coach comes off a bump and the wheels fall relative to the body. Elastomeric bumpers shall be provided at the limit of jounce travel. Rebound travel may be limited by elastomeric bumpers or hydraulically within the shock absorbers. Suspensions shall incorporate appropriate devices for automatic height control so that regardless of load the coach height relative to the centerline of the wheels does not change more than 1/, in. at any point from the height required. The safe operation of a coach cannot be impacted by ride height up to 1 in. from design normal ride height. TS 31.3.2 DAMPING Vertical damping of the suspension system shall be accomplished by hydraulic shock absorbers mounted to the suspension arms or axles and attached to an appropriate location on the chassis. Damping shall be sufficient to control coach motion to three cycles or less after hitting road perturbations. The shock absorber coaching shall be made of elastomeric material that will last the life of the shock absorber. The damper shall incorporate a secondary hydraulic rebound stop. TS 31.3.3 LUBRICATION All elements of steering, suspension and drive systems requiring scheduled lubrication shall be provided with grease fittings conforming to SAE Standard J534. These fittings shall be located for ease of inspection and shall be accessible with a standard grease gun from a pit or with the coach on a hoist. Each element requiring lubrication shall have its own grease fitting with a relief path. The lubricant specified shall be standard for all elements on the coach serviced by standard fittings and shall be required no less than every 6000 miles. TS 31.3.4 KNEELING A kneeling system shall lower the entrance(s) of the coach a minimum of 2 in. during loading or unloading operations regardless of load up to GVWR, measured at the longitudinal centerline of the entrance door(s) by the driver. The kneeling control shall provide the following functions: • Downward control must be held to allow downward kneeling movement. • Release of the control during downward movement must completely stop the lowering motion and hold the height of the coach at that position. • Upward control actuation must allow the coach to return to normal floor height without the driver having to hold the control. The brake and throttle interlock shall prevent movement when the coach is kneeled. The kneeling control shall be disabled when the coach is in motion. The coach shall kneel at a maximum rate of 1.25 in. per second at essentially a constant rate. After kneeling, the coach shall rise within 4 seconds to a Section 5 — Page 40 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 height permitting the coach to resume service and shall rise to the correct operating height within 7 seconds regardless of load up to GVWR. During the lowering and raising operation, the maximum vertical acceleration shall not exceed 0.2 g, and the jerk shall not exceed 0.3 g/second. An indicator visible to the driver shall be illuminated until the coach is raised to a height adequate for safe street travel. An audible warning alarm will sound simultaneously with the operation of the kneeler to alert passengers and bystanders. A warning light mounted near the curbside of the front door, a minimum 2.5 in. diameter amber lens, shall be provided that will blink when the kneel feature is activated. Kneeling shall not be operational while the wheelchair ramp is deployed or in operation. TS -32 WHEELS AND TIRES TS 32.1 WHEELS All wheels shall be interchangeable and shall be removable without a puller. Wheels shall be compatible with tires in size and load -carrying capacity. Front wheels and tires shall be balanced as an assembly per SAE J1986. Wheels quoted shall be brushed aluminum and an option price quoted for agencies that require polished aluminum wheels. Tire -pressure monitoring systems should be quoted as an option. TS 32.2 TIRES Tires shall be suitable for the conditions of transit service and sustained operation at the maximum speed capability of the coach. Load on any tire at GVWR shall not exceed the tire supplier's rating. Sufficient space shall be provided to allow the Agency to carry a spare tire, if required. TS -33 STEERING Hydraulically assisted steering shall be provided. The steering gear shall be an integral type with the number and length of flexible lines minimized or eliminated. Engine -driven hydraulic pump shall be provided for power steering. TS 33.1 STEERING AND TAG AXLES The front and tag axles shall be solid beam, non -driving with a load rating sufficient for the coach loaded to GVWR and shall be equipped with unitized grease type wheel bearings and seals. All friction points on the front axle shall be equipped with replaceable bushings or inserts and, if needed, lubrication fittings easily accessible from a pit or hoist. The steering geometry of the outside (front lock) wheel shall be within 2 deg of true Ackerman up to 50 percent lock measured at the inside (back lock) wheel. The steering geometry shall be within 3 degrees of true Ackerman for the remaining 100 percent lock measured at the inside (back lock) wheel. Section 5 — Page 41 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS 33.2 STEERING WHEEL TS 33.2.1 TURNING EFFORT Steering effort shall be measured with the coach at GVWR, stopped with the brakes released and the engine at normal idling speed on clean, dry, level, commercial asphalt pavement and the tires inflated to recommended pressure. Under these conditions, the torque required to turn the steering wheel 10 deg shall be no less than 5 ft - lbs and no more than 10 ft -lbs. Steering torque may increase to 70 ft -lbs when the wheels are approaching the steering stops, as the relief valve activates. Power steering failure shall not result in loss of steering control. With the coach in operation, the steering effort shall not exceed 55 lbs at the steering wheel rim, and perceived free play in the steering system shall not materially increase as a result of power assist failure. Gearing shall require no more than seven turns of the steering wheel lock -to -lock. Caster angle shall be selected to provide a tendency for the return of the front wheels to the straight position with minimal assistance from the driver. TS 33.2.2 STEERING WHEEL, GENERAL The steering wheel diameter shall be approximately 18 to 20 in.; the rim diameter shall be %a to 1Y. in. and shaped for firm grip with comfort for long periods of time. Steering wheel spokes and wheel thickness shall ensure visibility of the dashboard so that vital instrumentation is clearly visible at center neutral position (within the range of a 95th -percentile male, as described in SAE 1050a, Sections 4.2.2 and 4.2.3). Placement of steering column must be as far forward as possible, but either in line with or behind the instrument cluster. TS 33.2.3 STEERING COLUMN TILT The steering column shall have full tilt capability with an adjustment range of no less than 40 deg from the vertical and easily adjustable by the driver and shall be accessible by a 5th percentile female and 95th percentile male. TS 33.2.4 STEERING WHEEL TELESCOPIC ADJUSTMENT The steering wheel shall have full telescoping capability and have a minimum telescopic range of 2 in. and a minimum low-end adjustment of 29 in., measured from the top of the steering wheel rim in the horizontal position to the cab Floor at the heel point. Section 5 — Page 42 VVTA Solicitation No. 2013-04 Rev 4 Dated 829/13 TABLE 4 Steering Wheel Height' Relative to Angle of Slope At Minimum Telescopic Height Adjustment — At Maximum Telescopic Height Adjustment (5 (29 in.) in.) Angle of Slope — Height — Angle of Slope Height 0 deg 29 in. 0 deg 34 in. 15 deg 26.2 in. 15 deg 31.2 in. 25 deg 24.6 in. 25 deg 29.6 in. 35 deg 22.5 in. 35 deg 27.5 in. — 1. Measured from bottom portion closest to driver. TS -34 DRIVE AXLE The coach shall be driven by a heavy-duty axle with a load rating sufficient for the coach loaded to G\/WR. The drive axle shall have a design life to operate for not less than 300,000 miles on the design operating profile without replacement or major repairs. The lubricant drain plug shall be magnetic type. If a planetary gear design is employed, the oil level in the planetary gears shall be easily checked through the plug or sight gauge. The axle and driveshaft components shall be rated for both propulsion and retardation modes with respect to duty cycle. NOTE: The retardation duty cycle can be more aggressive than propulsion. The drive shaft shall be guarded to prevent hitting any critical systems, including brake lines, coach floor or the ground, in the event of a tube or universal joint failure. TS 34.1 NON -DRIVE AXLE The non -drive axle is the drive axle without the drive gear with a load rating sufficient for the load to GVW R. TS -35 TAG AXLES (COMMUTER COACH) A tag axle shall be located behind the drive axle. The tag axle shall be a solid beam type with steering capability. The tag axle shall have single tires the same size as the tires on the front and drive axles. Tag axle weight shall not exceed 14,000 lbs. With full passenger seating capacity, load on any axle shall Section 5 — Page 43 VVTA Solicitation No. 2013-04 Rev 4 Dated 829113 not exceed 22,400 lbs. Combined load capacity weight on the drive and tag axles shall not exceed 36,500 lbs. A tag axle unloading feature will allow full or partial unloading, or dumping of air from the tag axle air spring bellows. This feature enables weight to shift to the drive axle for more traction. Manual unloading valves are located inside the RH rear curbside service door. TS -36 TURNING RADIUS TABLE 5 Maximum Turning Radius Coach Length Maximum Turning Radius Agency Requirement (approximate) (see Figure 3) 45 ft 49 ft (TRO) FIGURE 3 Turning Radius Section 5 — Page 44 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS -37 BRAKES TS 37.1 SERVICE BRAKE Brakes shall be self-adjusting. Brake wear indicators (visible brake sensors) shall be provided on exposed push rods. Visible stroke indicators may be combined with electronic brake monitoring system and vehicle brake warning system to notify driver and maintenance of unsafe brake conditions. TS 37.2 ACTUATION Service brakes shall be controlled and actuated by a compressed air system. Force to activate the brake pedal control shall be an essentially linear function of the coach deceleration rate and shall not exceed 75 lbs at a point 7 in. above the heel point of the pedal to achieve maximum braking. The heel point is the location of the driver's heel when his or her foot is rested flat on the pedal and the heel is touching the floor or heel pad of the pedal. The ECU for the ABS system shall be protected, yet in an accessible location to allow for ease of service. The total braking effort shall be distributed among all wheels in such a ratio as to ensure equal friction material wear rate at all wheel locations. Manufacturer shall demonstrate compliance by providing a copy of a thermodynamic brake balance test upon request. TS 37.3 FRICTION MATERIAL The brake linings shall be made of non -asbestos material. In order to aid maintenance personnel in determining extent of wear, a provision such as a scribe line or a chamfer indicating the thickness at which replacement becomes necessary shall be provided on each brake lining. The complete brake lining wear indicator shall be clearly visible from the hoist or pit without removing backing plates. TS 37.4 HUBS AND DISCS Replaceable wheel bearing seals shall run on replaceable wear surfaces or be of an integral wear surface sealed design. Wheel bearing and hub seals and unitized hub assemblies shall not leak or weep lubricant when operating on the design operating profile for the duration of the initial manufacturer's warranty. The coach shall be equipped with disc brakes on all axles, and the brake discs shall allow machining of each side of the disc to obtain smooth surfaces per manufacturer's specifications. TS 37.5 PARKING/EMERGENCY BRAKE The parking brake shall be a spring -operated system, actuated by a valve that exhausts compressed air to apply the brakes. The parking brake may be manually enabled when the air pressure is at the operating level per FMVSS 121. Section 5 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS -38 PNEUMATIC SYSTEM TS 38.1 GENERAL The coach air system shall operate the air -powered accessories and the braking system with reserve capacity. New coaches shall not leak down more than 5 psi over a 15 -minute period of time as indicated on the dash gauge. Provision shall be made to apply shop air to the coach air systems. A quick disconnect fitting shall be easily accessible and located in the engine compartment and near the front bumper area for towing. Retained caps shall be installed to protect fitting against dirt and moisture when not in use. Air for the compressor shall be filtered. The air system shall be protected per FMVSS 121. TS 38.2 AIR COMPRESSOR An engine -driven air compressor shall be sized to charge the air system from 40 psi to the governor cut- off pressure in less than 4 minutes while not exceeding the fast idle speed setting of the engine. An electrically driven air compressor shall be sized to charge the air system from 40 psi to the governor cut-off pressure in less than 4 minutes while not exceeding the fast idle speed setting of the engine. TS 38.3 AIR LINES AND FITTINGS Air lines, except necessary flexible lines, shall conform to the installation and material requirements of SAE Standard A 149 for copper tubing with standard, brass, flared or ball sleeve fittings, or SAE Standard J844 for nylon tubing if not subject to temperatures over 200 °F. The air on the delivery side of the compressor where it enters nylon housing shall not be above the maximum limits as stated in SAE J844. Nylon tubing shall be installed in accordance with the following color -coding standards: • Green: Indicates primary brakes and supply. • Red: Indicates secondary brakes. • Brown: Indicates parking brake. • Yellow: Indicates compressor governor signal - Black: Indicates ignal.Black:Indicates accessories. Line supports shall prevent movement, flexing, tension, strain and vibration. Copper lines shall be supported to prevent the lines from touching one another or any component of the coach. To the extent practicable and before installation, the lines shall be pre-bent on a fixture that prevents tube flattening or excessive local strain. Copper lines shall be bent only once at any point, including pre -bending and installation. Rigid lines shall be supported at no more than 5 ft intervals. Nylon lines may be grouped and shall be supported at 30 in. intervals or less. The compressor discharge line between powerplant and body -mounted equipment shall be flexible convoluted copper or stainless steel line, or may be flexible Teflon hose with a braided stainless steel Section 5 — Page 46 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29113 jacket. Other lines necessary to maintain system reliability shall be flexible Teflon hose with a braided stainless steel jacket. End fittings shall be standard SAE or JIC brass or steel, flanged, swivel -type fittings. Flexible hoses shall be as short as practicable and individually supported. They shall not touch one another or any part of the coach except for the supporting grommets. Flexible lines shall be supported at 2 ft intervals or less. Air lines shall be clean before installation and shall be installed to minimize air leaks. All air lines shall be routed to prevent water traps to the extent possible. Grommets or insulated clamps shall protect the air lines at all points where they pass through understructure components. TS 38.4 AIR RESERVOIRS All air reservoirs shall meet the requirements of FMVSS Standard 121 and SAE Standard J10 and shall be equipped with drain plugs and guarded or flush type drain valves. Major structural members shall 'protect these valves and any automatic moisture ejector valves from road hazards. Reservoirs shall be sloped toward the drain valve. All air reservoirs shall have drain valves that discharge below floor level with lines routed to eliminate the possibility of water traps and/or freezing in the drain line. TS 38.5 AIR SYSTEM DRYER An air dryer shall prevent accumulation of moisture and oil in the air system. The air dryer system shall include one or more replaceable desiccant cartridges. ELECTRICAL, ELECTRONIC AND DATA COMMUNICATION SYSTEMS TS -39 OVERVIEW The electrical system will consist of vehicle battery systems and components that generate, distribute and store power throughout the vehicle. (e.g., generator, voltage regulator, wiring, relays and connectors). Electronic devices are individual systems and components that process and store data, integrate electronic information or perform other specific functions. The data communication system consists of the bi-directional communications networks that electronic devices use to share data with other electronic devices and systems. Communication networks are essential to integrating electronic functions, both on board the vehicle and off. Information level systems that require vehicle information for their operations or provide information shall adhere to J1939 data standard. Data communications systems are divided into three levels to reflect the use of multiple data networks: Powertrain level: Components related to the powertrain, including the propulsion system components (engine, transmission and hybrid units) and anti-lock braking system (ABS), which may include traction control. At a minimum, powertrain components consisting of the engine, Section 5 — Page 47 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 transmission, retarder, ASR and anti-lock braking systems shall be powered by a dedicated and isolated ignition supply voltage to ensure data communication between components exists when the vehicle ignition is switched to the "on" position. Information level: Components whose primary function is the collection, control or display of data that is not necessary to the safe drivability of the vehicle (i.e., the vehicle will continue to operate when those functions are inoperable). These components typically consist of those required for automatic vehicle location (AVL) systems, destination signs, fareboxes, passenger counters, radio systems, automated voice and signage systems, video surveillance and similar components. Multiplex level: Electrical or electronic devices controlled through input/output signals such as discrete, analog and serial data information (i.e., on/off switch inputs, relay or relay control outputs). Multiplexing is used to control components not typically found on the drivetrain or information levels, such as lights; wheelchair lifts; doors; heating, ventilation and air conditioning (HVAC) systems (if applicable); and gateway devices. FIGURE 4 Data Communications Systems Levels Information level Multiplex level Drivetrain level TS 39.1 MODULAR DESIGN Design of the electrical, electronic and data communication systems shall be modular so that each electronic device, apparatus panel, or wiring bundle is easily separable from its interconnect by means of connectors. Powerplant wiring shall be an independent wiring harness. Replacement of the engine compartment wiring harness(es) shall not require pulling wires through any bulkhead or removing any terminals from the wires. TS -40 ENVIRONMENTAL AND MOUNTING REQUIREMENTS The electrical system and its electronic components shall be capable of operating in the area of the vehicle in which they will be installed, as recommended in SAE J1455. Section 5 — Page 48 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 Electrical and electronic equipment shall not be located in an environment that will reduce the performance or shorten the life of the component or electrical system when operating within the design operating profile. As a recommendation, no vehicle component shall generate, or be affected by, electromagnetic interference or radio-frequency interference (EMI/RFI) that can disturb the performance of electrical/electronic equipment as defined in SAE J1113 and UNECE Council Directive 95/54 (R10). The Agency shall follow recommendations from coach manufacturers and subsystem suppliers regarding methods to prevent damage from voltage spikes generated from welding, jump starts, shorts, etc. TS 40.1 HARDWARE MOUNTING The mounting of the hardware shall not be used to provide the sole source ground, and ail hardware shall be isolated from potential EMI/RFI, as referenced in SAE J1113. All electrical/electronic hardware mounted in the interior of the vehicle shall be inaccessible to passengers and hidden from view unless intended to be viewed. The hardware shall be mounted in such a manner as to protect it from splash or spray. All electrical/electronic hardware mounted on the exterior of the vehicle that is not designed to be installed in an exposed environment shall be mounted in a sealed enclosure. All electrical/electronic hardware and its mounting shall comply with the shock and vibration requirements of SAE J1455. TS -41 GENERAL ELECTRICAL REQUIREMENTS TS 41.1 BATTERIES TS 41.1.1 LOW -VOLTAGE BATTERIES (24 V) Manufacturers should quote their standard battery package insuring that the battery compartment must be well -ventilated to prevent hydrogen buildup while protecting the compartment from road spray, water intrusion and de-icing chemicals. Each agency shall have the option of the following: 1. Four Group 31 Series deep -cycling maintenance -free battery units shall be provided. Each battery shall have a minimum of 700 cold -cranking amps. Each battery shall have a purchase date no more than 120days from the date of release for shipment to the Agency. 2. Two 8D battery units conforming to SAE Standard J537 shall be provided. Each battery shall have a minimum of 1150 cold cranking amps. Each battery shall have a purchase date no more than 120 days from the date of release, and shall be fully maintained prior to shipment to the Agency. 3. Two 8D maintenance -free batteries. Each battery shall have a purchase date no more than 120 days from date of release, and shall be fully maintained prior to shipment to the Agency. 4. Four Group 31 Series deep -cycling sealed non spillable maintenance free absorbed glass mat (AGM) batteries shall be provided. Each battery shall have a minimum of 1000 cold cranking Section 5 — Page 49 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 amps (CCA) at 0 OF. The batteries shall be designed and installed to withstand the operating environment. Each battery shall have a purchase date no more than one year from the date of release for shipment to the Agency. TS 41.1.2 BATTERY CABLES The battery terminal ends and cable ends shall be color -coded with red for the primary positive, black for negative and another color for any intermediate voltage cables. Positive and negative battery cables shall not cross each other if at all possible, shall be flexible and shall be sufficiently long to reach the batteries with the tray in the extended position without stretching or pulling on any connection and shall not lie directly on top of the batteries. Except as interrupted by the master battery switch, battery and starter wiring shall be continuous cables with connections secured by bolted terminals and shall conform to specification requirements of SAE Standard J1127—Type SGR, SGT, SGX or GXL and SAE Recommended Practice J541, with 2100 strand 4/0 cable or greater recommended. TS 41.1.3 JUMP START A jump-start connector, red for 24 V shall be provided in the engine compartment, equipped with dust cap and adequately protected from moisture, dirt and debris. TS 41.1.4 BATTERY COMPARTMENT The battery compartment shall prevent accumulation of snow, ice and debris on top of the batteries and shall be vented and self -draining. It shall be accessible only from the outside of the vehicle. All components within the battery compartment, and the compartment itself, shall be protected from damage or corrosion from the electrolyte. The inside surface of the battery compartment's access door shall be electrically insulated, as required, to prevent the battery terminals from shorting on the door if the door is damaged in an accident or if a battery comes loose. The battery compartment temperature should not exceed manufacturer's specification. The vehicle shall be equipped with a 12 V DC and 24 V DC quick disconnect switch(es). The battery compartment door shall conveniently accommodate operation of the 12 V DC and 24 V DC quick disconnect switch(es). The battery quick disconnect access door shall be identified with a decal. The decal size shall not be less than 3.5 x 5 in. (8.89 x 12.7 cm). The battery hold-down bracket shall be constructed of a nonconductive and corrosion -resistant material (plastic or fiberglass). This access door shall not require any special locking devices to gain access to the switch, and it shall be accessible without removing or lifting the panel. The door shall be flush -fitting and incorporate a spring tensioner or equal to retain the door in a closed position when not in use. The batteries shall be securely mounted on a stainless steel or equivalent tray that can accommodate the size and weight of the batteries. The battery tray, if applicable, shall pull out easily and properly Section 5 — Page 50 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 support the batteries while they are being serviced. The tray shall allow each battery cell to be easily serviced. A locking device shall retain the battery tray to the stowed position. If not located in the engine compartment, the same fire-resistant properties must apply to the battery compartment. No sparking devices should be located within the battery box. TS Design of the electrical, electronic and data communication systems shall be modular so that each electronic device, apparatus panel, or wiring bundle is easily separable from its interconnect by means of connectors. Powerplant wiring shall be an independent wiring hamess. Replacement of the engine compartment wiring harness(es) shall not require pulling wires through any bulkhead or removing any terminals from the wires The mounting of the hardware shall not be used to provide the sole source ground, and all hardware shall be isolated from potential EMI/RFI, as referenced in SAE J1111 All electrical/electronic hardware mounted in the interior of the vehicle shall be inaccessible to passengers and hidden from view unless intended to be viewed. The hardware shall be mounted in such a manner as to protect it from splash or spray. All electrical/electronic hardware mounted on the exterior of the vehicle that is not designed to be installed in an exposed environment shall be mounted in a sealed enclosure. All electrical/electronic hardware and its mounting shall comply with the shock and vibration requirements of Manufacturers should quote their standard battery package insuring that the battery compartment must be well -ventilated to prevent hydrogen buildup while protecting the compartment from road spray, water intrusion and de-icing chemicals. Each agency shall have the option of the following: 5. Four Group 31 Series deep -cycling maintenance -free battery units shall be provided. Each battery shall have a minimum of 700 cold -cranking amps. Each battery shall have a purchase date no more than 120days from the date of release for shipment to the Agency. 6. Two 8D battery units conforming to SAE Standard J537 shall be provided. Each battery shall have a minimum of 1150 cold cranking amps. Each battery shall have a purchase date no more than 120 days from the date of release, and shall be fully maintained prior to shipment to the Agency. 7. Two 8D maintenance -free batteries. Each battery shall have a purchase date no more than 120 days from date of release, and shall be fully maintained prior to shipment to the Agency. 8. Four Group 31 Series deep -cycling sealed non -spillable maintenance free absorbed glass mat (AGM) batteries shall be provided. Each battery shall have a minimum of 1000 cold cranking amps (CCA) at 0 °F. The batteries shall be designed and installed to withstand the operating environment. Each battery shall have a purchase date no more than one year from the date of release Section 5 — Page 51 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 The battery terminal ends and cable ends shall be color -coded with red for the primary positive, black for negative and another color for any intermediate voltage cables. Positive and negative battery cables shall not cross each other if at all possible, shall be flexible and shall be sufficiently long to reach the batteries with the tray in the extended position without stretching or pulling on any connection and shall not lie directly on top of the batteries. Except as interrupted by the master battery switch, battery and starter wiring shall be continuous cables with connections secured by bolted terminals and shall conform to specification requirements of SAE Standard J1127—Type SGR, SGT, SGX or GXL and SAE Recommended Practice A jump-start connector, red for 24 V shall be provided in the engine compartment, equipped with dust cap and TS 41.1.5 AUXILIARY ELECTRONIC POWER SUPPLY If required, gel -pack, or any form of sealed (non -venting) batteries used for auxiliary power are allowed to be mounted on the interior of the vehicle if they are contained in an enclosed, non -airtight compartment and accessible only to maintenance personnel. This compartment shall contain a warning label prohibiting the use of lead -acid batteries. The battery compartment shall prevent accumulation of snow, ice and debris on top of the batteries and shall be vented and self -draining. It shall be accessible only from the outside of the vehicle. All components within the battery compartment, and the compartment itself, shall be protected from damage or corrosion from the electrolyte. The inside surface of the battery compartment's access door shall be electrically insulated, as required, to prevent the battery terminals from shorting on the door if the door is damaged in an accident or if a battery comes loose. The battery compartment temperature should not exceed manufacturer's specification. The vehicle shall be equipped with a 12 V DC and 24 V DC quick disconnect switch(es). The battery compartment door shall conveniently accommodate operation of the 12 V DC and 24 V DC quick disconnect switch(es). The battery quick disconnect access door shall be identified with a decal. The decal size shall not be less than 3.5 x 5 in. (8.89 x 12.7 cm). The battery hold-down bracket shall be constructed of a nonconductive and corrosion -resistant material (plastic or fiberglass). This access door shall not require any special locking devices to gain access to the switch, and it shall be accessible without removing or lifting the panel. The door shall be flush -fitting and incorporate a spring tensioner or equal to retain the door in a closed position when not in use. The batteries shall be securely mounted on a stainless steel or equivalent tray that can accommodate the size and weight of the batteries. The battery tray, if applicable, shall pull out easily and properly support the batteries while they are being serviced. The tray shall allow each battery cell to be easily serviced. A locking device shall retain the battery tray to the stowed position. Section 5 — Page 52 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 If not located in the engine compartment, the same fire-resistant properties must apply to the battery compartment TS 41.1.6 MASTER BATTERY SWITCH The location of the master battery switch shall be clearly identified on the exterior access panel, be accessible in less than 10 seconds for deactivation and prevent corrosion from fumes and battery acid when the batteries are washed off or are in normal service. Turning the master switch off with the powerplant operating, during an emergency, shall shut off the engine and shall not damage any component of the electrical system. The master switch shall be capable of carrying and interrupting the total circuit load. TS 41.1.7 LOW -VOLTAGE GENERATION AND DISTRIBUTION The low -voltage generating system shall maintain the charge on fully charged batteries, except when the vehicle is at standard idle with a total low -voltage generator load exceeding 70 percent of the low - voltage generator nameplate rating. Voltage monitoring and over -voltage output protection (recommended at 32 V) shall be provided. Dedicated power and ground shall be provided as specified by the component or system manufacturer. Cabling to the equipment must be sized to supply the current requirements with no greater than a 5 percent volt drop across the length of the cable. TS 41.1.8 CIRCUIT PROTECTION All branch circuits, except battery -to -starting motor and battery-to-generator/alternator circuits, shall be protected by current -limiting devices such as circuit breakers, fuses or solid-state devices sized to the requirements of the circuit. Electronic circuit protection for the cranking motor shall be provided to prevent engaging of the motor for more than 30 seconds at a time to prevent overheating. The circuit breakers or fuses shall be easily accessible for authorized personnel. Fuses shall be used only where it can be demonstrated that circuit breakers are not practicable. This requirement applies to in-line fuses supplied by either the Contractor or a supplier. Fuse holders shall be constructed to be rugged and waterproof. All manual reset circuit breakers critical to the operation of the coach shall be mounted in a location convenient to the Agency mechanic with visible indication of open circuits. The Agency shall consider the application of automatic reset circuit breakers on a case-by-case basis. The Contractor shall show all in-line fuses in the final harness drawings. Any manually resettable circuit breakers shall provide a visible indication of open circuits. Any manually resettable circuit breakers shall provide a visible indication of open circuits. Circuit breakers or fuses shall be sized to a minimum of 15 percent larger than the total circuit load. The current rating for the wire used for each circuit must exceed the size of the circuit protection being used. Section 5 — Page 53 VVTA Solicitation No. 2013-04 Rev 4 Dated 829/13 TS 41.2 GROUNDS The battery shall be grounded to the vehicle chassis/frame at one location only, as close to the batteries as possible. When using a chassis ground system, the chassis shall be grounded to the frame in multiple locations, evenly distributed throughout the vehicle to eliminate ground loops. No more than five ground ring/spade terminal connections shall be made per ground stud with spacing between studs ensuring contactivity and serviceability. Electronic equipment requiring an isolated ground to the battery (i.e., electronic ground) shall not be grounded through the chassis. TS 41.3 LOW VOLTAGE/LOW CURRENT WIRING AND TERMINALS All power and ground wiring shall conform to specification requirements of SAE Recommended Practice J1127, J1128 and J1292. Double insulation shall be maintained as close to the junction box, electrical compartment or terminals as possible. The requirement for double insulation shall be met by wrapping the harness with plastic electrical tape or by sheathing all wires and harnesses with nonconductive, rigid or flexible conduit. Wiring shall be grouped, numbered and/or color -coded. Wiring harnesses shall not contain wires of different voltage classes unless all wires within the harness are insulated for the highest voltage present in the harness. Kinking, grounding at multiple points, stretching, and exceeding minimum bend radius shall be prevented. Strain -relief fittings shall be provided at all points where wiring enters electrical compartments. Grommets or other protective material shall be installed at points where wiring penetrates metal structures outside of electrical enclosures. Wiring supports shall be protective and non-conductive at areas of wire contact and shall not be damaged by heat, water, solvents or chafing. To the extent practicable, wiring shall not be located in environmentally exposed locations under the vehicle. Wiring and electrical equipment necessarily located under the vehicle shall be insulated from water, heat, corrosion and mechanical damage. Where feasible, front -to -rear electrical harnesses should be installed above the window line of the vehicle. All wiring harnesses over 5 ft long and containing at least five wires shall include 10 percent (minimum one wire) excess wires for spares. This requirement for spare wires does not apply to datalinks and communication cables. Wiring harness length shall allow end terminals to be replaced twice without pulling, stretching or replacing the wire. Terminals shall be crimped to the wiring according to the connector manufacturer's recommendations for techniques and tools. All cable connectors shall be locking type, keyed and sealed, unless enclosed in watertight cabinets or vehicle interior. Pins shall be removable, crimp contact type, of the correct size and rating for the wire being terminated. Unused pin positions shall be sealed with sealing plugs. Adjacent connectors shall use either different inserts or different insert orientations to prevent incorrect connections. Terminals shall be crimped, corrosion -resistant and full ring type or interlocking lugs with insulating ferrules. When using pressure type screw terminal strips, only stranded wire shall be used. Insulation clearance shall ensure that wires have a minimum of "visible clearance" and a maximum of two times the conduct or diameter or 1/16 in., whichever is less. When using shielded or coaxial cable, upon Section 5 — Page 54 VVTA Solicitation No. 2013-04 Rev 4 Dated 6/29/13 stripping of the insulation, the metallic braid shall be free from frayed strands that can penetrate the insulation of the inner wires. Ultra -sonic and T -splices may be used with 8 AWG or smaller wire. When a T -splice is used, it shall meet these additional requirements: It shall include a mechanical clamp in addition to solder on the splice. The wire shall support no mechanical load in the area of the splice. The wire shall be supported to prevent flexing. All splicing shall be staggered in the harness so that no two splices are positioned in the same location within the harness. Wiring located in the engine compartment shall be routed away from high -heat sources or shielded and/or insulated from temperatures exceeding the wiring and connector operating requirements. The instrument panel and wiring shall be easily accessible for service from the driver's seat or top of the panel. The instrument panel shall be separately removable and replaceable without damaging the instrument panel or gauges. Wiring shall have sufficient length and be routed to permit service without stretching or chafing the wires. TS 41.4 ELECTRICAL COMPONENTS All electrical components, including switches, relays, flashers and circuit breakers, shall be heavy-duty designs with either a successful history of application in heavy-duty vehicles or design specifications for an equivalent environment. All electric motors shall be heavy-duty brushless type where practical, and have a continuous duty rating of no less than 40,000 hours (except cranking motors, washer pumps, auxiliary heater pumps, defroster and wiper motors). All electric motors shall be easily accessible for servicing. TS 41.5 ELECTRICAL COMPARTMENTS All relays, controllers, flashers, circuit breakers and other electrical components shall be mounted in easily accessible electrical compartments. All compartments exposed to the outside environment shall be corrosion -resistant and sealed. The components and their functions in each electrical compartment shall be identified and their location permanently recorded on a drawing attached to the inside of the access panel or door. The drawing shall be protected from oil, grease, fuel and abrasion. The front compartment shall be completely serviceable from the driver's seat, vestibule or from the outside. "Rear start and run" controls shall be mounted in an accessible location in the engine compartment and shall be protected from the environment. Section 5 — Page 55 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS -42 GENERAL ELECTRONIC REQUIREMENTS If an electronic component has an internal real-time clock, it shall provide its own battery backup to monitor time when battery power is disconnected, and/or it may be updated by a network component. If an electronic component has an hour meter, it shall record accumulated service time without relying on battery backup. All electronic component suppliers shall ensure that their equipment is self -protecting in the event of shorts in the cabling, and also in over -voltage (over 32 V DC on a 24 V DC nominal voltage rating with a maximum of 50 V DC) and reverse polarity conditions. If an electronic component is required to interface with other components, it shall not require external pull-up and/or pull-down resistors. Where this is not possible, the use of a pull-up or pull-down resistor shall be limited as much as possible and easily accessible and labeled. TS 42.1 WIRING AND TERMINALS Kinking, grounding at multiple points, stretching and reducing the bend radius below the manufacturer's recommended minimum shall not be permitted. TS 42.1.1 DISCRETE 1/0 (INPUTS/OUTPUTS) All wiring to 1/0 devices, either at the harness level or individual wires, shall be labeled, stamped or color -coded in a fashion that allows unique identification at a spacing not exceeding 4 in. Wiring for each 1/0 device shall be bundled together. If the 1/0 terminals are the same voltages, then jumpers may be used to conned the common nodes of each 1/0 terminal. TS 42.1.2 SHIELDING All wiring that requires shielding shall meet the following minimum requirements. A shield shall be generated by connecting to a ground, which is sourced from a power distribution coach bar or chassis. A shield shall be connected at one location only, typically at one end of the cable. However, certain standards or special requirements, such as SAE J1939 or RF applications, have separate shielding techniques that also shall be used as applicable. When using shielded or coaxial cable, upon stripping of the insulation, the metallic braid shall be free from frayed strands, which can penetrate the insulation of the inner wires. To prevent the introduction of noise, the shield shall not be connected to the common side of a logic circuit. TS 42.1.3 COMMUNICATIONS The data network cabling shall be selected and installed according to the selected protocol requirements. The physical layer of all network communication systems shall not be used for any purpose other than communication between the system components, unless provided for in the network specifications. Communications networks that use powerline carriers (e.g., data modulated on a 24 V powerline) shall meet the most stringent applicable wiring and terminal specifications. Section 5 — Page 56 VVTA Solicitation No. 2013-04 Rev 4 Dated /29/13 TS 42.1.4 RADIO FREQUENCY (RF) RF components, such as radios, video devices, cameras, global positioning systems (GPS), etc., shall use coaxial cable to carry the signal. All RF systems require special design consideration for losses along the cable. Connectors shall be minimized, since each connector and crimp has a loss that will attribute to attenuation of the signal. Cabling should allow for the removal of antennas or attached electronics without removing the installed cable between them. If this cannot be done, then a conduit of sufficient size shall be provided for ease of attachment of antenna and cable assembly. The corresponding component vendors shall be consulted for proper application of equipment, including installation of cables. TS 42.1.5 AUDIO Cabling used for microphone level and line level signals shall be 22 AWG minimum with shielded twisted pair. Cabling used for amplifier level signals shall be 18 AWG minimum. TS -43 MULTIPLEXING TS 43.1 GENERAL The primary purpose of the multiplexing system is control of components necessary to operate the vehicle. This is accomplished by processing information from input devices and controlling output devices through the use of an internal logic program. Versatility and future expansion shall be provided for by expandable system architecture. The multiplex system shall be capable of accepting new inputs and outputs through the addition of new modules and/or the utilization of existing spare inputs and outputs. All like components in the multiplex system shall be modular and interchangeable with self-diagnostic capabilities. The modules shall be easily accessible for troubleshooting electrical failures and performing system maintenance. Multiplex input/output modules shall use solid-state devices to provide extended service life and individual circuit protection. TS 43.2 SYSTEM CONFIGURATION Multiplexing may either be distributed or centralized. A distributed system shall process information on multiple control modules within the network. A centralized system shall process the information on a single control module. Either system shall consist of several modules connected to form a control network. 43.2.1 1/0 SIGNALS The input/output for the multiplex system may contain four types of electrical signals: discrete, modulating, analog or serial data. Discrete signals shall reflect the on/off status of switches, levers, limit switches, lights, etc. Analog signals shall reflect numerical data as represented by a voltage signal (0-12 V, 10-24 V, etc.) or current signal (4-20 mA). Both types of analog signals shall represent the status of variable devices such as Section 5 — Page 57 VVTA Solicitation No. 2013-04 Rev 4 Dated/2& 9/13 rheostats, potentiometers, temperature probes, etc. Serial data signals shall reflect ASCII or alphanumeric data used in the communication between other on -board components. TS -44 DATA COMMUNICATIONS TS 44.1 GENERAL All data communication networks shall be either in accordance with a nationally recognized interface standard, such as those published by SAE, IEEE or ISO, or shall be published to the Agency with the following minimum information: • Protocol requirements for all timing issues (bit, byte, packet, inter -packet timing, idle line timing, etc.) packet sizes, error checking and transport (bulk transfer of data to/from the device). • Data definition requirements that ensure access to diagnostic information and performance characteristics. • The capability and procedures for uploading new application or configuration data. • Access to revision level of data, application software and firmware. The capability and procedures for uploading new firmware or application software. Evidence that applicable data shall be broadcast to the network in an efficient manner such that the overall network integrity is not compromised. Any electronic vehicle components used on a network shall be conformance tested to the corresponding network standard. TS 44.2 DRIVETRAIN LEVEL Drivetrain components, consisting of the engine, transmission, retarder, anti-lock braking system and all other related components, shall be integrated and communicate fully with respect to vehicle operation with data using SAE Recommended Communications Protocols such as J1939 and/or J1708/J1587 with forward and backward compatibilities or other open protocols. At a minimum, drivetrain components consisting of the engine, transmission, retarder ASR, and anti-lock braking systems shall be powered by a dedicated and isolated ignition supply voltage to ensure data communication among components exists when the vehicle ignition is switched to the "on" position. TS 44.2.1 DIAGNOSTICS, FAULT DETECTION AND DATA ACCESS Drivetrain performance, maintenance and diagnostic data, and other electronic messages shall be formatted and transmitted on the communications networks. The drivetrain level shall have the ability to record abnormal events in memory and provide diagnostic codes and other information to service personnel. At a minimum, this network level shall provide live/fail status, current hardware serial number, software/data revisions and uninterrupted timing functions. TS 44.2.2 PROGRAMMABILITY (SOFTWARE) The drivetrain level components shall be programmable by the Agency with limitations as specified by the subsystem Supplier. Section 5 — Page 58 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS 44.3 MULTIPLEX LEVEL TS 44.3.1 DATA ACCESS At a minimum, information shall be made available via a communication port on the multiplex system. The location of the communication port shall be easily accessible. A hardware gateway and/or wireless communications system are options if requested by the Agency. The communication port(s) shall be located as specified by the Agency. TS 44.3.2 DIAGNOSTICS AND FAULT DETECTION The multiplex system shall have a proven method of determining its status (system health and input/output status) and detecting either active (online) or inactive (offline) faults through the use of on- board visual/audible indicators. In addition to the indicators, the system shall employ an advanced diagnostic and fault detection system, which shall be accessible via either a personal computer or a handheld unit. Either unit shall have the ability to check logic function. The diagnostic data can be incorporated into the information level network or the central data access system. An option shall be made available to provide a mock-up board A mock-up board, where key components of the multiplexing system are replicated on a functional model, shall be provided as a tool for diagnostic, design verification and training purposes, if required by an agency. The mock-up board should be priced separately in the Pricing Schedule. TS 44.3.3 PROGRAMMABILITY (SOFTWARE) The multiplex system shall have security provisions to protect its software from unwanted changes. This shall be achieved through any or all of the following procedures: Password protection Limited distribution of the configuration software Limited access to the programming tools required to change the software Hardware protection that prevents undesired changes to the software Provisions for programming the multiplex system shall be possible through a PC or laptop. The multiplex system shall have proper revision control to ensure that the hardware and software are identical on each vehicle equipped with the system. Revision control shall be provided by all of the following: • Hardware component identification where labels are included on all multiplex hardware to identify components • Hardware series identification where all multiplex hardware displays the current hardware serial number and firmware revision employed by the module • Software revision identification where all copies of the software in service display the most recent revision number • A method of determining which version of the software is currently in use in the multiplex system Section 5 — Page 59 V VTA Solicitation No. 2013-04 Rev _4_Dated 829/13 TS 44.4 ELECTRONIC NOISE CONTROL Electrical and electronic subsystems and components on all coaches shall not emit electromagnetic radiation that will interfere with on -board systems, components or equipment, telephone service, radio or TV reception, or violate regulations of the Federal Communications Commission. Electrical and electronic subsystems on the coaches shall not be affected by external sources of RFI/EMI. This includes, but is not limited to, radio and TV transmission, portable electronic devices including computers in the vicinity of or onboard the coaches, AC or DC power lines and RFI/EMI emissions from other vehicles. DRIVER PROVISIONS, Controls and instrumentation TS -45 DRIVER'S AREA CONTROLS TS 45.1 GENERAL In general when designing the driver's area within the Coach, it is recommended that SAE J833, "Human Physical Dimensions," be used. Switches and controls shall be divided into basic groups and assigned to specific areas, in conformance with SAE Recommended Practice J680, Revised 1988, "Location and Operation of Instruments and Controls in Motor Truck Gabs," and be essentially within the hand reach envelope described in SAE Recommended Practice J287, "Driver Hand Control Reach." TS 45.2 GLARE The driver's work area shall be designed to minimize glare to the extent possible. Objects within and adjacent to this area shall be matte black or dark gray in color wherever possible to reduce the reflection of light onto the windshield. The use of polished metal and light-colored surfaces within and adjacent to the drivers area shall be avoided. TS 45.3 VISORS/SUN SHADES Adjustable sun visor(s) shall be provided for the driver's windshield and the driver's side window. Visors shall be shaped to minimize light leakage between the visor and windshield pillars. Visors shall store out of the way and shall not obstruct airflow from the climate control system or interfere with other equipment, such as the radio handset or the destination control. Deployment of the visors shall not restrict vision of the rearview mirrors. Visor adjustments shall be made easily by hand with positive locking and releasing devices and shall not be subject to damage by over -tightening. Sun visor construction and materials shall be strong enough to resist breakage during adjustments. Visors may be transparent but shall not allow a visible light transmittance in excess of 10 percent. Visors, when deployed, shall be effective in the driver's field of view at angles more than 5 deg above the horizontal. Section 5 — Page 60 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS 45.4 DRIVER'S CONTROLS Frequently used controls must be in easily accessible locations. These include the door control, kneel control, windshield wiper/washer controls, ramp, and lift and run switch. Any switches and controls necessary for the safe operation of the coach shall be conveniently located and shall provide for ease of operation. They shall be identifiable by shape, touch and permanent markings. Controls also shall be located so that passengers may not easily tamper with control settings. All panel -mounted switches and controls shall be marked with easily read identifiers. Graphic symbols shall conform to SAE Recommended Practice J2402, "Road Vehicles — Symbols For Controls, Indicators, and Tell Tales," where available and applicable. Color of switches and controls shall be dark with contrasting typography or symbols. Mechanical switches and controls shall be replaceable, and the wiring at these controls shall be serviceable from a convenient location. Switches, controls and instruments shall be dust- and water- resistant. TS 45.5 NORMAL COACH OPERATION INSTRUMENTATION AND CONTROLS The following list identifies some common coach controls used to operate the coach. These controls are either frequently used or critical to the operation of the coach. They shall be located within easy reach of the operator. The operator shall not be required to stand or tum to view or actuate these controls unless specified otherwise. Systems or components monitored by onboard diagnostics system shall be displayed in clear view of the operator and provide visual and/or audible indicators. The intensity of indicators shall permit easy determination of on/off status in bright sunlight but shall not cause a distraction or visibility problem at night. All indicators shall be illuminated using backlighting. The indicator panel shall be located in Area 1 or Area 5, within easy view of the operator instrument panel. All indicators shall have a method of momentarily testing their operation. The audible alarm shall be tamper-resistant and shall have an outlet level between 80 and 83 dBA when measured at the location of the operator's ear. On -board displays visible to the operator shall be limited to indicating the status of those functions described herein that are necessary for the operation of the coach. All other indicators needed for diagnostics and their related interface hardware shall be concealed and protected from unauthorized access. Table 6 represents instruments and alarms. The intent of the overall physical layout of the indicators shall be in a logical grouping of systems and severity nature of the fault. Please provide drawings of dash and controls with locations. Consideration shall be provided for future additions of spare indicators as the capability of onboard diagnostic systems improves. Blank spaces shall contain LEDs. Section 5 — Page 61 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TABLE 6 (Commuter Coach) Commuter Coach Instruments and Alarms Device Description Location Function Master control for coach, Visual/ Audible Master run Rotary, four- Side console off, day run, night run and switch position detent clearance ID lights Engine start, Approved Side console Activates engine starter front momentary switch motor Engine start, Approved Engine Activates engine starter rear momentary switch compartment motor Permits running engine Engine run, Three -position Engine from rear start, normal Amber light rear toggle switch compartment front run position and off Provides selection of Drive selector Touch panelswitch Side console propulsion: forward, Gear selection reverse and neutral Permits selection of passenger ventilation: off, HVAC Switch or switches Side console cool, heat, low fan, high to control HVAC fan or full auto with on/off only Permits supplemental Driver's Rotary, three- Side console or ventilation: fan off, low or ventilation position detent dash left wing high Rotary, three- Side console or Permits defroster: fan off, Defroster fan position detent dash left wing low, medium or high Defroster Side console or Adjusts defroster water temperature Variable position dash left wing flow and temperature One -variable Variable speed control of Windshield rotary position Dash left wing left and right windshield wiper operating both wipers wipers Section 5 — Page 62 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 TABLE 6 (Commuter Coach) Commuter Coach Instruments and Alarms Device Description Location Function Visual/ Audible Windshield Push button Dash left wing Activates windshield washer washers Provides adjustment for Dash panel Rotary rheostat or Side console or light intensity in night run lights stepping switch dash left wing position Selects mode of Interior lights Three -position Side console passenger compartment switch lighting: off, on, normal Two -position Selects high idle speed of Fast idle switch Side console engine Permits operation of ramp WC ramp/ Two -position Side console or and kneel operations at Amber light kneel enable switch' dash right wing each door remote panel Front door Front door Permits ramp and kneel ramp/kneel Two -position keyed switch ' remote or dash activation from front door Amber light enable right wing area, key required' Front door Three -position Right side of Permits deploy and stow Red light ramp momentary switch steering wheel of front ramp Permits kneeling Amber or red Three -position Front door activation and raise and dash indicator; Front kneel momentary switch remote normal at front door exterior alarm remote location and amber light Activates emergency Recessed push radio alarm at dispatch Silent alarm button, NO and NC contacts Side console and permits covert microphone and/or momentary enables destination sign emergency message Section 5 — Page 63 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TABLE 6 (Commuter Coach) Commuter Coach Instruments and Alarms Device Description Location Function Visual/ Audible Momentary on/off Triggers event equipment, Video system momentary switch Side console triggers event light on Amber light event switch with plastic guard dash — Permits two -axis Left remote Four -position Side console adjustment of left exterior mirror toggle type mirror Permits two -axis Right remote Four -position Side console adjustment of right mirror toggle type exterior mirror Switch or Permits heating of outside Mirror heater temperature Side console mirrors when required activated Permits open/close ' Five -position Passenger handle type detent Side console, control of front and rear Red light door control or two momentary forward passenger doors push buttons Rear doorSide Two -position console, Allows driver to override override switch in forward activation of rear door approved location passenger tape switches Engine Momentary switch Permits driver to override shutdown with operation Side console auto engine shutdown override protection Hazard Two -position Side console or Activates emergency Two green lights flashers switch dash right wing flashers Fire Red push button Dash left wing or Permits driver to override with protective dash center and manually discharge Red light suppression cover fire suppression system Section 5 – Page 64 V VTA Solicitation No. 2013-04 Rev 4 Dazed 829/13 TABLE 6 (Commuter Coach) Commuter Coach Instruments and Alarms Device Description Mobile data Location Function Facilitates driver Visual/Audible LCD display with Mobile data terminal coach Above right interaction with visual status and terminal operator interface dash wing communication system text messages panel Farebox coach and master log -on Facilitates driver Farebox operator interface Near farebox interaction with farebox LCD display interface panel system Facilitates driver Destination Destination sign In approved interaction with LCD display sign interface interface panel location destination sign system, manual entry Momentary push button (two Activates left and right Two green lights Tum signals required) raised Left foot panel tum signals and optional from other audible indicator switches Permits driver to manually PA manual Momentary push In approved activate public address button location microphone Permits driver to make announcements with both Low -profile Low -profile Steering column hands on the wheel and microphone discrete mounting focusing on road conditions Permits driver to toggle High beam Detented push In approved between low and high Blue light button PPV location beam Permits driver to apply i_ Red light Parking brake 'Pneumatic Side console or dash left wing and release parking brake Section 5 — Page 65 VVTA Solicitation No. 2013-04 Rev 4 Dated 829/13 TABLE 6 (Commuter Coach) Commuter Coach Instruments and Alarms Device Description Location Function permits driver to push and Visual/ Audible Park brake Vertical side of release Pneumatic PPV the side console hold to release brakes or dash center Hill holder Two -position Side console Applies brakes to prevent momentary switch coach from rolling Permits technician to raise Remote engine Rotary rheostat Engine and lower engine RPM speed compartment from engine compartment Permits driver override to Master door/ Multi -pole toggle, Out of operator's disable door and Red light interlock detented reach brake/throttle interlock Warning Dash panel Illuminates to warn driver interlocks Red indicator light that interlocks have been Red light deactivated center deactivated. Within reach of Permits driver override to Retarder Multi -pole switch operator or disable brake Red light disable detented approved retardation/regeneration location Alarm Push button Approved Permits driver to acknowledge alarm acknowledge momentary locationcondition Permits driver to override Rear door In sign passenger Multi -pole toggle, compartment or rear door passenger sensor disable detented driver's barrier system sensingstem compartment Indicator/ Momentary switch Dash center Permits driver to activate All visuals and alarm testtest panel of sentry, indicators audibles button °r programming and audible alarms Section 5 — Page 66 VVTA Solicitation No. 2013-04 Rev 4 Dated 09/13 TABLE 6 (Commuter Coach) Commuter Coach Instruments and Alarms Device Description Location Function Visual/ Audible 110 V power Approved Property to specify what Auxiliary power receptacle location function to supply Speedometer, Visual indication of speed odometer, and and distance traveled, Speedometer diagnostic Dash center accumulated vehicle Visual capability, 5 -mile panel mileage, fault condition increments display Air pressure Primary and Dash center Visual indication of Red light and secondary, panel primary and secondary air buzzer gauge 5 psi increments systems Coach operator Property specific Indication of fire detection Buzzer and red Fire detection display or dash center activation by zone/location light Door Sensing of door Indication of rear door Red light and obstruction obstruction Dash center sensitive edge activation buzzer Door not properly Property specific Indication of rear door not Buzzer or alarm Door ajar closed or dash center properly closed and red light Sensing low Low system air primary and Indication of low air Buzzer and red pressure secondary air tank Dash center system pressure light pressure Methane detection Detection of Property specific Detects system failure No start condition, amber function system integrity or dash center light Methane Indication of 20% LED emergency property specific Detects levels of methane Flashing red at detection light (LEL) or dash center 20% LEL Methane Indication of 50% Property specific Detects levels of methane Solid red at 50% detection LEL or dash center LEL Section 5 — Page 67 VVTA Solicitation No. 2017-04 Rev 4 Dated 8/29/13 TABLE 6 (Commuter Coach) Commuter Coach Instruments and Alarms Device Description Location Function Visual/ Audible Low coolant indicator may be Engine coolant supplied as Within driver's Detects low coolant Amber light indicator audible alert and sight condition visual and/or text message Coolant temperature Hot engine indicator may be Within driver's Detects hot engine supplied as condition and initiates Red light indicator audible alert and sight time delay shutdown visual and/or text message Engine oil pressure indicator Detects low engine oil Low engine oil may be supplied Within driver's pressure condition and Red light pressure as audible alert sight initiates time -delayed indicator and visual and/or shutdown text message ABS indicator Detects system Dash center Displays system failure Amber light status HVAC Detects system Dash center Displays system failure Amber or red indicator status light Detects no charge Charging condition and optionally Red light system Detect charging Dash center detects battery high, low, flashing or solid indicator system status imbalance, no charge based on (72/24 V) condition, and initiates condition time -delayed shutdown Section 5 — Page 68 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TABLE 6 (Commuter Coach) Commuter Coach Instruments and Alarms Device Description Location Function Visual/ Audible Bike rack Detects bike rack Indication of bike rack not Amber or red deployed Dash center being in fully stowed light indicator position position Analog gauge, Indication of fuel tank Fuel tank level graduated based Dash center level/pressure on fuel type Displays level of DEF tank DEF gauge Level Indicator Center dash and indicates with warning Red light light when low Active Indication of electric Amber or red regeneration Detects status Dash center regeneration light Audible and Warning indication for amberwarning Turntable Detects status Dash center hinge locking and red light if locked Momentarily release Turntable Interlock Side console interlock brakes due to momentary switch overangled condition TS 45.6 DRIVER FOOT CONTROLS Accelerator and brake pedals shall be designed for ankle motion. Foot surfaces of the pedals shall be faced with wear -resistant, nonskid, replaceable material. TS 45.6.1 PEDAL ANGLE The vertical angle of the accelerator and brake pedals shall be determined from a horizontal plane regardless of the slope of the cab floor. The accelerator and brake pedals shall be positioned at an angle of 37 to 50 deg at the point of initiation of contact and extend downward to an angle of 10 to 18 deg at full throttle. Section 5 — Page 69 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 The location of the brake and accelerator pedals shall be determined by the manufacturer, based on space needs, visibility, lower edge of windshield and vertical H -point. TS 45.6.2 PEDAL DIMENSIONS AND POSITION The floor -mounted accelerator pedal shall be 10 to 12 in. long and 3 to 4 in. wide. Clearance around the pedal must allow for no interference precluding operation. The accelerator and brake pedals shall be positioned such that the spacing between them, measured at the heel of the pedals, is between 1 and 2 in. Both pedals should be located approximately on the same plane coincident to the surface of the pedals. TS 45.7 DRIVER FOOT SWITCHES Floor -Mounted Foot Control Platform. The angle of the turn signal platform shall be determined from a horizontal plane, regardless of the slope of the cab floor. The turn signal platform shall be angled at a minimum of 10 deg and a maximum of 37 deg. It shall be located no closer to the seat front than the heel point of the accelerator pedal. The control switches for the tum signals shall be mounted on an inclined, floor -mounted stainless steel enclosure or metal plate mounted to an incline integrated into the driver's platform, located to the left of the steering column. The location and design of this enclosure shall be such that foot room for the operator is not impeded. The inclined mounting surface shall be skid -resistant. All other signals, including high beam and public address system, shall be in approved locations. The foot switches shall be UL -listed, heavy-duty type, of a rugged, corrosion -resistant metal construction. The foot switches for the directionals shall be momentary type, while those for the PA system and the high beam shall be latching type. The spacing of the switches shall be such that inadvertent simultaneous deflection of switches is prevented. Other Floor -Mounted Controls; The following may be floor mounted, momentary or latching, as identified by the Agency: hazard silent alarm PA system TS -46 DRIVER'S AMENITIES TS 46.1 COAT HANGER Coat Hanger; A suitable hanger shall be installed in a convenient, approved location for the driver's coat. Section 5 — Page 70 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/1 TS 46.2 STORAGE BOX An enclosed driver storage area shall be provided with a positive latching door and/or lock. The minimum size is 2750 in.3. TS -47 WINDSHIELD WIPERS AND WASHERS TS 47.1 WINDSHIELD WIPERS The coach shall be equipped with a windshield wiper for each half of the windshield. At 60 mph, no more than 10 percent of the wiped area shall be lost due to windshield wiper lift. For two-piece windshields, both wipers shall park along the center edges of the windshield glass. For single -piece windshields, wipers shall park along the bottom edge of the windshield. Windshield wiper motors and mechanisms shall be easily accessible for repairs or service. The fastener that secures the wiper arm to the drive mechanism shall be corrosion -resistant. Wipers shall be electric motor driven with two speeds and adjustable intermittent wiper action. TS 47.2 WINDSHIELD WASHERS The windshield washer system, when used with the wipers, shall deposit washing fluid evenly and completely wet the entire wiped area. The windshield washer system shall have a minimum 3 -gallon reservoir, located for easy refilling from outside the coach. Reservoir pumps, lines and fittings shall be corrosion -resistant and must include a means to determine fluid level. Section 5 — Page 71 VVIR Solicitation No. 2013-04 Rev 4 Dated 8/29/13. TS -48 DRIVER'S SEAT FIGURE 5 Driver's Seat TS 48.1 DIMENSIONS Head rest Seat back Arm rest Seat belt Seat base The driver's seat shall be comfortable and adjustable so that people ranging in size from a 95th - percentile male to a 5th -percentile female may operate the coach. Contractor to provide make and model numbers of driver seat options available and specifications. TS 48.2 SEAT BELT The belt assembly should be an auto -locking retractor (ALR).All seat belts should be stored in automatic retractors. The belts shall be mounted to the seat frame so that the driver may adjust the seat without resetting the seat belt. The seat and seatbelt assemblies as installed in the coach shall withstand static horizontal fomes as required in FMVSS 207 and 210. Lap Belt Length The lap belt assembly shall be 72 in. in length with an 8 in. extension Section 5 — Page 72 VVTA Solicitation No. 2013-04 Rev 4 Dated28 9/13 TS 48.3 SEAT CONTROL LOCATIONS While seated, the driver shall be able to make seat adjustments by hand without complexity, excessive effort or being pinched. Adjustment mechanisms shall hold the adjustments and shall not be subject to inadvertent changes. TS 48.4 SEAT STRUCTURE AND MATERIALS Cushions Cushions shall be fully padded with at least 3 in, of materials in the seating areas at the bottom and back. Cushion Materials Foam and fabric that meets FTA Docket 90A. TS 48.5 PEDESTAL Powder -coated steel. TS 48.6 SEAT OPTIONS The following options shall be made available to the agencies with separate pricing included in the proposal: • heated seat • seat alarm • fabric options • seat air vent • side bolsters adjustments • silicone seat cushion TS 48.7 MIRRORS TS 48.7.1 EXTERIOR MIRRORS The coach shall be equipped with corrosion -resistant, outside rearview mirrors mounted with stable supports to minimize vibration. Mirrors shall be firmly attached to the coach to minimize vibration and to prevent loss of adjustment with a breakaway mounting system. Mirrors shall permit the driver to view the roadway along the sides of the coach, including the rear wheels. Mirrors should be positioned to prevent blind spots. Mirrors shall retract or fold sufficiently to allow coach washing operations but avoid contact with windshield. Section 5 — Page 73 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 Curbside Mirrors The curbside rearview mirror shall be mounted so that its lower edge is no less than 76 in. above the street surface. A lower mount may be required due to mirror configuration requests. Remote Adjustment of Street and Curbside Mirrors The driver shall be able to adjust all four external rear view mirrors remotely while seated in the driving position. The controls for remote positioning of the mirrors can be a single or dual switch or device. Mirrors must be heated and be operated in conjunction with the driver's heater or with separate controls. TS 48.7.2 INTERIOR MIRRORS Mirrors shall be provided for the driver to observe passengers throughout the coach without leaving the seat and without shoulder movement. The driver shall be able to observe passengers in the fronVentrance and rear/exit areas (if applicable), anywhere in the aisle, and in the rear seats. WINDOWS TS -49 GENERAL A minimum of 12,000 sq in. of window area, including operator and door windows, shall be required on each side of the standard configuration coach. TS -50 WINDSHIELD The windshield shall permit an operators field of view as referenced in SAE Recommended Practice J1050. The vertically upward view shall be a minimum of 14 deg, measured above the horizontal and excluding any shaded band. The vertically downward view shall permit detection of an object 3'/2 ft high no more than 2 ft in front of the coach. The horizontal view shall be a minimum of 90 deg above the line of sight .Any binocular obscuration due to a center divider may be ignored when determining the 90 deg requirement, provided that the divider does not exceed a 3 deg angle in the operator's field of view. Windshield pillars shall not exceed 10 deg of binocular obscuration. The windshield shall be designed and installed to minimize external glare as well as reflections from inside the coach. The windshield shall be easily replaceable by removing zip -locks from the windshield retaining moldings. Bonded -in-place windshields shall not be used. Winglets may be bonded. TS 50.1 GLAZING The windshield glazing material shall have a'% in. nominal thickness laminated safety glass conforming to the requirements of ANSI Z26.1 Test Grouping AS -1 and the recommended practices defined in SAE J673. Section 5 — Page 74 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 Shaded Band The upper portion of the windshield above the driver's field of view shall have a dark, shaded band and marked AS -3, with a minimum luminous transmittance of 5 percent when tested in accordance to ASTM D-1003. TS -51 DRIVER'S SIDE WINDOW The driver's side window shall be the sliding type, requiring only the rear half of the sash to latch upon closing, and shall open sufficiently to permit the seated operator to easily adjust the street -side outside rearview mirror. When in an open position, the window shall not rattle or close during braking. This window section shall slide in tracks or channels designed to last the service life of the coach. The operator's side window shall not be bonded in place and shall be easily replaceable. The glazing material shall have a single -density tint. The driver's view, perpendicular through operator's side window glazing, should extend a minimum of 33 in. (840 mm) to the rear of the heel point on the accelerator, and in any case must accommodate a 95th percentile male operator. The view through the glazing at the front of the assembly should begin not more than 26 in. (560 mm) above the operator's floor to ensure visibility of an under -mounted convex mirror. Driver's window construction shall maximize ability for full opening of the window. The driver's side window glazing material shall have a '/4 in. nominal thickness laminated safety glass conforming to the requirements of ANSI Z26.1-1996 Test Grouping AS -2 and the recommended practices defined in SAE J673. The design shall prevent sections from freezing closed in the winter. Light transmittance shall be 75 percent on the glass area below 53 in. from the operator platform floor. On the top -fixed -over -bottom -slider configuration, the top fixed area above 53 in. may have a maximum 5 percent light transmittance. Standard Driver's Side Window, Traditional Frame: top fixed over bottom slider • non -egress TS -52 SIDE WINDOWS TS 52.1 CONFIGURATION Side windows shall not be bonded in place, but shall be easily replaceable without disturbing adjacent windows and shall be mounted so that flexing or vibration from engine operation or normal road excitation is not apparent. All aluminum and steel material will be treated to prevent corrosion. Section 5 — Page 75 V VTA Solicitation No. 2013-04 Rev 4 Dated 829/13 TS 52.2 EMERGENCY EXIT (EGRESS) CONFIGURATION All side windows shall be fixed in position, except as necessary to meet the emergency escape requirements. Standard Passenger Side Window Configurations Agency to choose from the following options: • traditional frame full fixed openable windows with inward -opening transom panels openable windows with sliding transom panels TS 52.3 MATERIALS Safety Glass Glazing Panels Contractor to supply technical specifications on standard glazing used with options listed as line items. All glazing must meet FMVSS, DOT and all other federal and state regulations. Specifications and Options should be listed for solar transmittance and heat absorption. NOTE: All glass treatments must be permanent, within the glass and/or in the center membrane. Surface films are not permitted. SHGC and light transmission performance shall be defined by the National Fenestration Rating Council. HEATING, VENTILATING AND AIR CONDITIONING TS -53 CAPACITY AND PERFORMANCE The HVAC climate control system shall be capable of controlling the temperature and maintaining the humidity levels of the interior of the coach as defined in the following paragraphs. With the coach running at the design operating profile with corresponding door opening cycle, and carrying a number of passengers equal to 150 percent of the seated load, the HVAC system shall control the average passenger compartment temperature within a range between 60 and SO OF, while maintaining the relative humidity to a value of 50 percent or less. The system shall maintain these conditions while subjected to any outside ambient temperatures within a range of 10 to 95 OF and at any ambient relative humidity levels between 5 and 50 percent. When the coach is operated in outside ambient temperatures of 95 to 115 OF, the interior temperature of the coach shall be permitted to rise 0.5 OF for each degree of exterior temperature in excess of 95 OF. Section 5 — Page 76 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 When the coach is operated in outside ambient temperatures in the range of -10 to 10 OF, the interior temperature of the coach shall not fall below 55 OF while the coach is running on the design operating profile. System capacity testing, including pull-down/warm-up, stabilization and profile, shall be conducted in accordance to APTA's Recommended Practice "Transit Coach HVAC System Instrumentation and Performance Testing." NOTE: The recommended locations of temperature probes are only guidelines and may require slight modifications to address actual coach design. Care must be taken to avoid placement of sensing devices in the immediate path of an air duct outlet. In general, the locations are intended to accurately represent the interior passenger area. Additional testing shall be performed as necessary to ensure compliance to performance requirements stated herein. Capacity and Performance Requirements The air-conditioning portion of the HVAC system shall be capable of reducing the passenger compartment temperature from 115 to 70 OF t 3 OF in less than 30 minutes after system engagement. Engine temperature shall be within the normal operating range at the time of start-up of the cool -down test, and the engine speed shall be limited to fast idle, which may be activated by a driver -controlled device. During the cool -down period, the refrigerant pressure shall not exceed safe high -side pressures, and the condenser discharge air temperature, measured 6 in. from the surface of the coil, shall be less than 45 OF above the condenser inlet air temperature. No simulated solar load shall be used. There shall be no passengers on board, and the doors and windows shall be closed. The air conditioning system shall meet these performance requirements using R407C. TS -54 CONTROLS AND TEMPERATURE UNIFORMITY The HVAC system excluding the driver's heater/defroster shall be centrally controlled with an advanced electronic/diagnostic control system with provisions for extracting/reading data. The system shall be compliant with J1939 Communication Protocol for receiving and broadcasting of data. Hot engine coolant water shall be delivered to the HVAC system driver's defroster/heater and other heater cores by means of an auxiliary coolant pump, sized for the required flow, which is brushless and seal less having a minimum maintenance -free service life for both the brushless motor and the pump of at least 40,000 hours at full power. Manually Adjustable Temperature Control Set Point The climate control system shall have the provision to allow the driver to adjust the temperature control set point at a minimum of between 68 and 72 OF. From then on, all interior climate control system requirements shall be attained automatically, unless re -adjusted by the driver. Section 5 — Page 77 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 The driver shall have full control over the defroster and driver's heater. The driver shall be able to adjust the temperature in the driver's area through air distribution and fans. The interior climate control system shall switch automatically to the ventilating mode If the refrigerant compressor or condenser fan fails. Interior temperature distribution shall be uniform to the extent practicable to prevent hot and/or cold spots. After stabilization with doors closed, the temperatures between any two points in the passenger compartment in the same vertical plane, and 6 to 72 in. above the floor, shall not vary by more than 5 OF with doors closed. The interior temperatures, measured at the same height above the floor, shall not vary more than t5 OF from the front to the rear from the average temperature determined in accordance with APTA's "Recommended Instrumentation and Performance Testing for Transit Coach Air Conditioning System." Variations of greater than t5 OF will be allowed for limited, localized areas provided that the majority of the measured temperatures fall within the specified requirement. TS 54.1 AUXILIARY HEATER No auxiliary heater. TS -55 AIR FLOW TS 55.1 PASSENGER AREA The cooling mode of the interior climate control system shall introduce air into the coach at or near the ceiling height at a minimum rate of 25 cubic ft per minute (cfm) per passenger based on the standard configuration coach carrying a number of passengers equal to 150 percent of the seated load. Airflow shall be evenly distributed throughout the coach, with air velocity not exceeding 100 ft per minute on any passenger. The ventilating mode shall provide air at a minimum flow rate of 20 cfm per passenger. Airflow may be reduced to 15 cfm per passenger (150 percent of seated load) when operating in the heating mode. The fans shall not activate until the heating element has warmed sufficiently to ensure at least 70 OF air outlet temperature. The heating air outlet temperature shall not exceed 120 OF under any normal operating conditions. The climate control blower motors and fan shall be designed such that their operation complies with the interior noise level requirements. Requirement for 10 Percent "Fresh Air" Mixture The air shall be composed of no less than 10 percent outside air. TS 55.2 DRIVER'S AREA The coach interior climate control system shall deliver at least 100 cfm of air to the driver's area when operating in the ventilating and cooling modes. Adjustable nozzles shall permit variable distribution or shutdown of the airflow. Airflow in the heating mode shall be reduced proportionally to the reduction of airflow into the passenger area. The windshield defroster unit shall meet the requirements of SAE Section 5 — Page 78 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 Recommended Practice J382, "Windshield Defrosting Systems Performance Requirements," and shall have the capability of diverting heated air to the driver's feet and legs. The defroster or interior climate control system shall maintain visibility through the driver's side window. TS 55.3 CONTROLS FOR THE CLIMATE CONTROL SYSTEM (CCS) The controls for the driver's compartment for heating, ventilation and cooling systems shall be integrated and shall meet the following requirements: The heat/defrost system fan shall be controlled by a separate switch that has an "off' position and at least two positions for speed control. All switches and controls shall preclude the possibility of clothing becoming entangled, and shields shall be provided, if required. If the fans are approved by the Agency, an "on/off' switch shall be located to the right or or near the main defroster switch. A manually operated control valve shall control the coolant flow through the heater core. If a cable -operated manual control valve is used, then the cable length shall be kept to a minimum to reduce cable seizing. Heater water control valves shall be "positive" type, closed or open. The method of operating remote valves shall require the concurrence of the Agency project manager. TS 55.4 DRIVER'S COMPARTMENT REQUIREMENTS A separate heating, ventilation and defroster system for the driver's area shall be provided and shall be controlled by the driver. The system shall meet the following requirements: The heater and defroster system shall provide heating for the driver and heated air to completely defrost and defog the windshield, driver's side window, and the front door glasses in all operating conditions. Fan(s) shall be able to draw air from the coach body interior and/or exterior through a control device and pass it through the heater core to the defroster system and over the driver's feet. A minimum capacity of 100 cfm shall be provided. The driver shall have complete control of the heat and fresh airflow for the driver's area. The defroster supply outlets shall be located at the lower edge of the windshield. These outlets shall be durable and shall be free of sharp edges that can catch clothes during normal daily cleaning. The system shall be such that foreign objects such as coins or tickets cannot fall into the defroster air outlets. Adjustable ball vents or louvers shall be provided at the left of the driver's position to allow direction of air onto the side windows. A ventilation system shall be provided to ensure driver comfort and shall be capable of providing fresh air in both the foot and head areas. Vents shall be controllable by the driver from the normal driving position. Decals shall be provided, indicating "operating instructions" and "open' and "closed" positions. When closed, vents shall be sealed to prevent the migration of water or air into the coach. TS 55.5 DRIVER'S COOLING Separate Dedicated Evaporator; using a separate, dedicated evaporator, the climate control system shall be designed to maintain the driver's compartment temperatures within the range specified for the passenger compartment. The unit shall operate when the climate control switch is in the "Cool" position. It shall have a separate thermostatic control. Section 5 — Page 79 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS -56 AIR FILTRATION Air shall be filtered before entering the AC system and being discharged into the passenger compartment. The filter shall meet the ANSI/ASHRAE 52.1 requirement for 5 percent or better atmospheric dust spot efficiency, 50 percent weight arrestance, and a minimum dust holding capacity of 120 g per 1000 cfm cell. Air filters shall be easily removable for service. Air filters shall be cleanable. TS -57 ROOF VENTILATORS Each ventilator shall be easily opened and closed manually. When open with the coach in motion, this ventilator shall provide fresh air inside the coach. The ventilator shall cover an opening area no less than 425 sq in. and shall be capable of being positioned as a scoop with either the leading or trailing edge open no less than 4 in., or with all four edges raised simultaneously to a height of no less than 3'/2 in. An escape hatch shall be incorporated into the roof ventilator. Roof ventilator(s) shall be sealed to prevent entry of water when closed. TS -58 MAINTAINABILITY Manually controlled shut-off valves in the refrigerant lines shall allow isolation of the compressor and dehydrator filter for service. To the extent practicable, self-sealing couplings utilizing O-ring seals shall be used to break and seal the refrigerant lines during removal of major components, such as the refrigerant compressor. Shut-off valves may be provided in lieu of self-sealing couplings. The condenser shall be located to efficiently transfer heat to the atmosphere and shall not ingest air warmed above the ambient temperature by the coach mechanical equipment, or to discharge air into any other system of the coach. The location of the condenser shall preclude its obstruction by wheel splash, road dirt or debris. HVAC components located within 6 in. of floor level shall be constructed to resist damage and corrosion. High and low refrigerant pressure electronic gauges to be located in the return air area. TS -59 ENTRANCE/EXIT AREA HEATING No requirements for entrance/exit area heating. TS -60 FLOOR -LEVEL HEATING Sufficient heaters shall be provided with ducting to blow warm air upward through a cavity in the wall and discharge the warm air at the base of the windows. Control of the warm wall heating shall be through the main heating system electronic control. Section 5 — Page 80 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 EXTERIOR PANELS, FINISHES and Exterior Lighting TS -61 DESIGN The coach shall have a clean, smooth, simple design, primarily derived from coach performance requirements and passenger service criteria. The exterior and body features, including grilles and louvers, shall be shaped to facilitate cleaning by automatic coach washers without snagging washer brushes. Water and dirt shall not be retained in or on any body feature to freeze or bleed out onto the coach after leaving the washer. The body and windows shall be sealed to prevent leaking of air, dust or water under normal operating conditions and during cleaning in automatic coach washers for the service life of the coach. Exterior panels shall be sufficiently stiff to minimize vibration, drumming or flexing while the coach is in service. When panels are lapped, the upper and forward panels shall act as a watershed. However, if entry of moisture into the interior of the vehicle is prevented by other means, then rear cap panels may be lapped otherwise. The windows, hatches and doors shall be able to be sealed. Accumulation of spray and splash generated by the coach's wheels shall be minimized on windows and mirrors. TS 61.1 MATERIALS Body materials shall be selected and the body fabricated to reduce maintenance, extend durability and provide consistency of appearance throughout the service life of the coach. Detailing shall be kept simple, and add-on devices and trim shall be minimized and integrated into the basic design. TS -62 PEDESTRIAN SAFETY Exterior protrusions along the side and front of the coach greater than '/2 in. and within 80 in. of the ground shall have a radius no less than the amount of the protrusion. The exterior rearview mirrors, cameras and required lights and reflectors are exempt from the protrusion requirement. Advertising frames shall protrude no more than '/a in. from the body surface. Grilles, doors, bumpers and other features on the sides and rear of the coach shall be designed to minimize toeholds or handholds. Exterior protrusions shall not cause a line -of -sight blockage for the driver. TS -63 REPAIR AND REPLACEMENT TS 63.1 SIDE BODY PANELS Structural elements supporting exterior body panels shall allow side body panels below the windows to be repaired. Section 5 — Page 81 VVTA Solicitation No. 2013-04 Rev 4 Dated 829/13 TS -64 RAIN GUTTERS Rain gutters shall be provided to prevent water flowing from the roof onto the passenger doors and driver's side window. When the coach is decelerated, the gutters shall not drain onto the windshield, driver's side window or door boarding area. Cross sections of the gutters shall be adequate for proper operation. TS -65 LICENSE PLATE PROVISIONS Provisions shall be made to mount standard -size U.S./Canada license plates per SAE J686 on the front and rear of the coach. These provisions shall direct -mount or recess the license plates so that they can be cleaned by automatic coach -washing equipment without being caught by the brushes. The rear license plate provision shall be illuminated per SAE J587. Default Requirement for Rub Rails Rub rails composed of flexible, resilient material shall be provided to protect both sides of the coach body from damage caused by minor sideswipe accidents with automobiles. Rub rails shall have vertical dimensions of no less than 2 in. (50 mm) with the centerline no higher than 35 in. above the ground between the wheel wells. The rub rails shall withstand impacts of 200 ft -lbs of energy from a steel -faced spherical missile no less than 9 in. in diameter and of a 500 Ib load applied anywhere along their length by a rigid plate 1 It in length, wider than the rub rail, and with a Ya in. end radii, with no visible damage to the rub rail, retainer or supporting structure. The rub rail may be discontinued at doorways, wheel wells and articulated joints if applicable. A damaged portion of the rub rail shall be replaceable without requiring removal or replacement of the entire rub rail. NOTE: Installation of rub rails may preclude the installation and/or size of exterior advertising signs or racks. TS -66 FENDER SKIRTS Features to minimize water spray from the coach in wet conditions shall be included in wheel housing design. Any fender skirts shall be easily replaceable. They shall be flexible if they extend beyona the allowable body width. Wheels and tires shall be removable with the fender skirts in place. TS 66.1 SPLASH APRONS Standard Splash Aprons Splash aprons, composed of 1/4 in. minimum composition or rubberized fabric, shall be installed behind and/or in front of wheels as needed to reduce road splash and to protect under floor components. The splash aprons shall extend downward to within 6 in. off the road surface at static conditions. Apron widths shall be no less than tire widths. Splash aprons shall be bolted to the coach understructure. Section 5 — Page 82 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 Splash aprons and their attachments shall be inherently weaker than the structure to which they are attached. The flexible portions of the splash aprons shall not be included in the road clearance measurements. Splash apron shall be installed as necessary to protect the wheelchair loading device from road splash. Other splash aprons shall be installed where necessary to protect coach equipment. TS -67 SERVICE COMPARTMENTS AND ACCESS DOORS TS 67.1 ACCESS DOORS Conventional doors shall be used for the engine compartment and for all auxiliary equipment compartments including doors for checking the quantity and adding to the engine coolant, engine lubricant and transmission fluid. Access openings shall be sized for easy performance of tasks within the compartment, including tool operating space. Access doors shall be of rugged construction and shall maintain mechanical integrity and function under normal operations throughout the service life of the coach. They shall close flush with the body surface. All doors shall be hinged at the top or on the forward edge and shall be prevented from coming loose or opening during transit service or in coach washing operations. All access doors shall be retained in the open position. Latch handles shall be flush with, or recessed behind, the body contour and shall be sized to provide an adequate grip for opening. Access doors, when opened, shall not restrict access for servicing other components or systems. If precluded by design, the manufacturer shall provide door design information specifying how the requirements are met. TS 67.2 ACCESS DOOR LATCH/LOCKS Requirement for Latches on Access Doors Access doors larger than 100 sq in. in area shall be equipped with corrosion -resistant flush -mounted latches or locks except for coolant and fuel fill access doors. All such access doors that require a tool to open shall be standardized throughout the vehicle. Agencies may define any required locks or latches for access doors and prices should be quoted separately. TS -68 BUMPERS TS 68.1 LOCATION Bumpers shall provide impact protection for the front and rear of the coach with the top of the bumper being 27 in., ±2 in., above the ground. Bumper height shall be such that when one coach is parked behind another, a portion of the bumper faces will contact each other. TS 68.2 FRONT BUMPER No part of the coach, including the bumper, shall be damaged as a result of a 5 mph impact of the coach at curb weight with a fixed, flat barrier perpendicular to the coach's longitudinal centerline. The bumper shall return to its pre -impact shape within 10 minutes of the impact. The bumper shall protect the coach Section 5 — Page 83 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 from damage as a result of 6.5 mph impacts at any point by the common carriage with contoured impact surface defined in Figure 2 of FMVSS 301 loaded to 4000 lbs. parallel to the longitudinal centerline of the coach. It shall protect the coach from damage as a result of 5.5 mph impacts into the corners at a 30 deg angle to the longitudinal centerline of the coach. The energy absorption system of the bumper shall be independent of every power system of the coach and shall not require service or maintenance in normal operation during the service life of the coach. The bumper may increase the overall coach length specified by no more than 7 in. TS 68.3 REAR BUMPER No part of the coach, including the bumper, shall be damaged as a result of a 2 mph impact with a fixed, flat barrier perpendicular to the longitudinal centerline of the coach. The bumper shall return to its pre - impact shape within 10 minutes of the impact. When using a yard tug with a smooth, flat plate bumper 2 ft wide contacting the horizontal centerline of the rear bumper, the bumper shall provide protection at speeds up to 5 mph, over pavement discontinuities up to 1 in. high, and at accelerations up to 2 mph/see. The rear bumper shall protect the coach when impacted anywhere along its width by the common carriage with contoured impact surface defined in Figure 2 of FMVSS 301 loaded to 4000 lbs., at 4 mph parallel to or up to a 30 deg angle to the longitudinal centerline of the coach. The rear bumper shall be shaped to preclude unauthorized riders standing on the bumper. The bumper shall not require service or maintenance in normal operation during the service life of the coach. The bumper may increase the overall coach length specified by no more than 7 in. TS 68.4 BUMPER MATERIAL Bumper material shall be corrosion -resistant and withstand repeated impacts of the specified loads without sustaining damage. These bumper qualities shall be sustained throughout the service life of the coach. TS -69 FINISH AND COLOR TS 69.1 APPEARANCE All exterior surfaces shall be smooth and free of wrinkles and dents. Exterior surfaces to be painted shall be properly prepared as required by the paint system Supplier prior to application of paint to ensure a proper bond between the basic surface and successive coats of original paint for the service fife of the coach. Drilled holes and cutouts in exterior surfaces shall be made prior to cleaning, priming and painting, where possible, to prevent corrosion. The coach shall be painted prior to installation of exterior lights, windows, mirrors and other items that are applied to the exterior of the coach. Body filler materials may be used for surface dressing, but not for repair of damaged or improperly fitted panels. Paint shall be applied smoothly and evenly with the finished surface free of visible dirt and the following other imperfections: blisters or bubbles appearing in the topcoat film Section 5 — Page 84 VVTA Solicitation No. 2013-04 Rev 4 Dated 9/29/13 • chips, scratches or gouges of the surface finish • cracks in the paint film • crater; where paint failed to cover due to surface contamination • overspray • peeling • runs or sags from excessive flow and failure to adhere uniformly to the surface chemical stains and water spots dry patches due to incorrect mixing of paint activators • buffing swirls All exterior finished surfaces shall be impervious to diesel fuel, gasoline and commercial cleaning agents. Finished surfaces shall resist damage by controlled applications of commonly used graffiti - removing chemicals. Proper adhesion between the basic surface and successive coats of the original paint shall be measured using an Elcometer adhesion tester as outlined in ASTM D4541-85. Adhesion shall be a minimum 300 ft -lbs. The coach manufacturer shall supply test samples of the exterior surface for each step of the painting process that may be subject to adhesion testing per ASTM G4541-87 and ASTM D4145-85. ASTM D4541-93 may be used for inspection testing during assembly of the vehicle. Standard Contractor exterior paint finish quality. Agencies will provide approved paints, color scheme and graphics. TS -70 DECALS, NUMBERING AND SIGNING Monograms, numbers and other special signing shall be applied to the inside and outside of the coach as required. Signs shall be durable and fade-, chip- and peel -resistant. They may be painted signs, decals or pressure -sensitive appliqu6s. All decals shall be installed per the decal Supplier recommendations. Signs shall be provided in compliance with the ADA requirements defined in 49 C.F.R. Part 38, Subpart B, 38.27. Agencies will provide a list of signs and/or decals that are required above and beyond those specified in federal, state, and local regulations. TS 70.1 PASSENGER INFORMATION ADA priority seating signs as required and defined by 49 C.F.R. shall be provided to identify the seats designated for passengers with disabilities. Requirements for a public information system in accordance with 49 C.F.R. shall be provided. Section 5 — Page 85 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/13 TS -71 EXTERIOR LIGHTING All exterior lights shall be LED and designed to prevent entry and accumulation of moisture or dust. Lamps, lenses and fixtures shall be interchangeable to the extent practicable. Two hazard lamps at the rear of the coach shall be visible from behind when the engine service doors are opened. Light lenses shall be designed and located to prevent damage when running the vehicle through an automatic coach washer. Contractor to provide details of exterior lighting system. TS 71.1 BACKUP LIGHT/ALARM Visible and audible warnings shall inform following vehicles or pedestrians of reverse operation. Visible reverse operation warning shall conform to SAE Standard J593. Audible reverse operation warning shall conform to SAE Recommended Practice J994 Type C or D. TS 71.2 DOORWAY LIGHTING Lamps at the front and rear passenger doorways (if applicable) shalt comply with ADA requirements and shall activate only when the doors open. These lamps shall illuminate the street surface to a level of no less than 1 foot-candle for a distance of 3 ft outward from the outboard edge of the door threshold. The lights may be positioned above or below the lower daylight opening of the windows and shall be shielded to protect passengers' eyes from glare. Lights to be LED if available that meet ADA requirements. TS 71.3 TURN SIGNALS Standard Tum Signals LED Turn -signal lights shall be provided on the front, rear, curb and street sides of the coach in accordance with federal regulations. TS 71.4 HEADLIGHTS Headlamps shall be designed for ease of replacement. Standard OEM headlight installation shall be provided in accordance with federal regulations and contractor is to supply details of headlight installation. Daytime Running Lights Headlamps shall incorporate a daytime running light feature. LED Headlamps shall be LED/halogen, sealed beam. Section 5 — Page 86 VVTA Solicitation No. 2013-04 Rev 4 Dated B/24l13 TS 71.5 BRAKE LIGHTS LED Brake lights shall be provided in accordance with federal regulations Brake lights shall be provided in accordance with federal regulations. Coach shall include red, high and center mount brake lamp(s) along the backside of the coach in addition to the lower brake lamps required under FMVSS. The high and center mount brake lamps) shall illuminate steadily with brake application. TS 71.6 SERVICE AREA LIGHTING (INTERIOR AND EXTERIOR) LED lamps shall be provided in the engine and all other compartments where service may be required to generally illuminate the area for night emergency repairs or adjustments. These service areas shall include, but not be limited to, the engine compartment, the communication box, junction/apparatus panels and passenger door operator compartments. Lighting shall be adequate to light the space of the service areas to levels needed to complete typical emergency repairs and adjustments. The service area lamps shall be suitable for the environment in which they are mounted. Engine compartment lamps shall be controlled by a switch mounted near the rear start controls. All other service area lamps shall be controlled by switches mounted on or convenient to the lamp assemblies. Power to the service area lighting shall be programmable. Power shall latch on with activation of the switch and shall be automatically discontinued (timed out) after 30 minutes to prevent damage caused by inadvertently leaving the service area lighting switch in the "on" position after repairs are made. INTERIOR PANELS AND FINISHES TS -72 GENERAL REQUIREMENTS Materials shall be selected on the basis of maintenance, durability, appearance, safety, flammability and tactile qualities. Materials shall be strong enough to resist everyday abuse and be vandalism and corrosion resistant. Trim and attachment details shall be kept simple and unobtrusive. Interior trim shall be secured to avoid resonant vibrations under normal operational conditions. Interior surfaces more than 10 in. below the lower edge of the side windows or windshield shall be shaped so that objects placed on them fall to the floor when the coach is parked on a level surface. Any components and other electrical components within close proximity to these surfaces shall also be resistant to this cleaning method. Section 5 — Page 87 V VTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 TS -73 INTERIOR PANELS Panels shall be easily replaceable and tamper resistant. They shall be reinforced, as necessary, to resist vandalism and other rigors of transit coach service. Individual trim panels and parts shall be interchangeable to the extent practicable. TS -73.1 DRIVER'S BARRIER A barrier or bulkhead between the driver and the street -side front passenger seat shall be provided. The barrier shall minimize glare and reflections in the windshield directly in front of the barrier from interior lighting during night operation. Location and shape must permit full seat travel and reclining possibilities that can accommodate the shoulders of a 95th -percentile male. The partition shall have a side return and stanchion to prevent passengers from reaching the driver by standing behind the driver's seat. The lower area between the seat and panel must be accessible to the driver. The partition must be strong enough in conjunction with the entire partition assembly for mounting of such equipment as flare kits, fire extinguishers (1.2 kg), microcomputer, public address amplifier, etc. The panel should be properly attached to minimize noise and rattles. The driver's barrier shall extend from the floor area to the ceiling and from the coach wall to the first stanchion immediately behind the driver to provide security to the driver and to limit passenger conversation. TS 73.2 MODESTY PANELS Sturdy divider panels constructed of durable, unpainted, corrosion -resistant material complementing the interior shall be provided to act as both a physical and visual barrier for seated passengers. Design and installation of modesty panels located in front of forward -facing seats shall include a handhold or grab handle along its top edge. These dividers shall be mounted on the sidewall and shall project toward the aisle no farther than passenger knee projection in longitudinal seats or the aisle side of the transverse seats. Modesty panels shall extend from at least the window opening of the side windows, and those forward of transverse seats shall extend downward to 1 and 1% in. above the floor. Panels forward of longitudinal seats shall extend to below the level of the seat cushion. Dividers positioned at the doorways, where applicable, shall provide no less than a 2'/ in. clearance between the modesty panel and a fully open, inward opening door, or the path of a deploying flip -out ramp to protect passengers from being pinched. Modesty panels installed at doorways shall be equipped with grab rails if passenger assists are not provided by other means. The modesty panel and its mounting shall withstand a static force of 250 lbs applied to a 4 x 4 in. area in the center of the panel without permanent visible deformation. TS 73.3 FRONT END The entire front end of the coach shall be sealed to prevent debris accumulation behind the dash and to prevent the driver's feet from kicking or fouling wiring and other equipment. The front end shall be free of protrusions that are hazardous to passengers standing at the front of the standee line area of the coach Section 5 — Page 88 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 during rapid decelerations. Paneling across the front of the coach and any trim around the driver's compartment shall be formed metal or composite material. Composite dash panels shall be reinforced as necessary, vandal -resistant and replaceable. All colored, painted and plated parts forward of the driver's barrier shall be finished with a surface that reduces glare. Any mounted equipment must have provision to support the weight of equipment. TS 73.4 REAR BULKHEAD The rear bulkhead and rear interior surfaces shall be material suitable for exterior skin; painted and finished to exterior quality; or paneled with melamine -type material, composite, scratch -resistant plastic or carpeting and trimmed with stainless steel, aluminum or composite. The rear bulkhead paneling shall be contoured to fit the ceiling, side walls and seat backs so that any litter or trash will tend to fall to the floor or seating surface when the coach is on a level surface. Any air vents in this area shall be louvered to reduce airflow noise and to reduce the probability of trash or liter being thrown or drawn through the grille. If it is necessary to remove the panel to service components located on the rear bulkhead, then the panel shall be hinged or shall be able to be easily removed and replaced. Grilles where access to or adjustment of equipment is required shall be heavy duty and designed to minimize damage and limit unauthorized access. TS 73.5 HEADLINING Ceiling panels shall be made of durable, corrosion resistant, easily cleanable material. Headlining shall be supported to prevent buckling, drumming or flexing and shall be secured without loose edges. Headlining materials shall be treated or insulated to prevent marks due to condensation where panels are in contact with metal members. Moldings and trim strips, as required to make the edges tamperproof, shall be stainless steel, aluminum or plastic, colored to complement the ceiling material. Headlining panels covering operational equipment that is mounted above the ceiling shall be on hinges for ease of service but retained to prevent inadvertent opening. TS 73.6 FASTENING Interior panels shall be attached so that there are no exposed unfinished or rough edges or rough surfaces. Fasteners should be corrosion resistant. Panels and fasteners shall not be easily removable by passengers. Exposed interior fasteners should be minimized, and where required shall be tamper resistant. TS 73.7 INSULATION Any insulation material used between the inner and outer panels shall minimize the entry and/or retention of moisture. Insulation properties shall be unimpaired during the service life of the coach. Any insulation material used inside the engine compartment shall not absorb or retain oils or water and shall be designed to prevent casual damage that may occur during maintenance operations. The combination of inner and outer panels on the sides, roof, wheel wells and ends of the coach, and any material used between these panels, shall provide a thermal insulation sufficient to meet the interior Section 5 — Page 89 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 temperature requirements. The coach body shall be thoroughly sealed so that the driver or passengers cannot feel drafts during normal operations with the passenger doors closed. FTA Docket 90-A All insulation materials shall comply with the Recommended Fire Safety Practices defined in FTA Docket 90-A, dated October 20, 1993, TS 73.8 FLOOR COVERING The floor covering shall have a non-skid walking surface that remains effective in all weather conditions. The floor covering, as well as transitions of flooring material to the main floor and to the entrance and exit area, shall be smooth and present no tripping hazards. Seams shall be sealed/welded per manufacturer's specifications. The standee line shall be approximately 2 in. wide and shall extend across the coach aisle. The color and pattern shall be consistent throughout the floor covering. Any areas on the floor that are not intended for standees, such as areas "swept" during passenger door operation, shall be clearly and permanently marked. The floor shall be easily cleaned and shall be arranged to minimize debris accumulation. A one-piece center strip shall extend from the vertical wall of the rear settee between the aisle sides of transverse seats to the standee line. If the floor is of a bi-level construction, then the center strip shall be one piece at each level. The covering between the center strip and the wheel housings may be separate pieces. At the rear door, however, a separate strip as wide as the door shall extend from the center strip to the outboard edge of the rear/exit area. The floor under the seats shall be covered with smooth surface flooring material. The floor covering shall closely fit the sidewall in a fully sealed butt joint or extend to the top of the cove. TS 73.9 INTERIOR LIGHTING The light source shall be located to minimize windshield glare, with distribution of the light focused primarily on the passengers' reading plane while casting sufficient light onto the advertising display. The lighting system may be designed to form part of or the entire air distribution duct. The lens material shall be translucent polycarbonate. Lenses shall be designed to effectively "mask" the light source. Lenses shall be sealed to inhibit incursion of dust and insects yet be easily removable for service. Access panels shall be provided to allow servicing of components located behind light panels. If necessary, the entire light fixture shall be hinged. TS 73.10 PASSENGER First Row Lights The first light on each side (behind the driver and the front door) is normally turned on only when the front door is opened, in "night run' and "night park." As soon as the door closes, these lights shall go out. These lights shall be turned on at any time if the switch is in the "on" position. Section 5 — Page 90 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 All interior lighting shall be turned off whenever the transmission selector is in reverse and the engine run switch is in the "on" position. The interior lighting design shall require the approval of the Agency. LED lights. TS 73.11 DRIVER'S AREA The driver's area shall have a light to provide general illumination, and it shall illuminate the half of the steering wheel nearest the driver to a level of 5 to 10 foot-candles. TS 73.12 SEATING AREAS A minimum 10 -module parcel rack without dividers and compartment doors shall be furnished over all two -passenger seating positions except in the wheelchair door area. Retention cords shall run the length of the rack housing. The parcel rack edge, running along the full length of the aisle, shall incorporate a handhold for use by standees. Passenger headroom, measured from the rack end to the top of the seat headrest, shall be a minimum 17 in. (432 mm). Interior window post caps shall be ABS, thermo formed plastic, off-white in color to provide a clean finished appearance. The interior of the rack shall be vinyl covered aluminum to complement the interior. Parcel racks shall be supported by polycarbonate glass filled hangers spaced approximately 40 in. (1016 mm) apart. Total capacity shall be a minimum 109 ft3 (3 m') to allow for ample storage space for carry -on items. Passenger service modules mounted on the underside of the parcel rack shall include individually controlled and adjustable LED passenger reading lights; an exit signal push button, red in color; and individual air distribution outlets. These outlets shall be adjustable from fully closed to fully open position. A minimum of 26 speakers shall also be provided in the cluster panels for the driver -controlled public address system. Speakers shall broadcast, in a clear tone, announcements that are clearly perceived from all seat positions at approximately the same volume level. Passengers utilizing the securement systems shall be provided identical amenities as provided for all other passengers, except that the parcel rack shall be deleted in the area of the wheelchair lift door. Separate and independent notification will be provided on the dashboard indicator panel for stop request notification from securement positions. TS 73.13 VESTIBULES/DOORS Floor surface in the aisles shall be a minimum of 2 foot-candles, and the vestibule area in accordance with ADA requirements. TS 73.14 STEP LIGHTING Step lighting for the intermediate steps between lower and upper floor levels shall be a minimum of 4 foot-candles and shall illuminate in all engine run positions: The step lighting shall be low profile to minimize tripping and snagging hazards for passengers and shall be shielded as necessary to protect passengers' eyes from glare. Section 5 — Page 91 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129/1 TS 73.15 FAREBOX LIGHTING Farebox Light A light fixture shall be mounted in the ceiling above the farebox location. The fixture shall be capable of projecting a concentrated beam of light on the farebox. This light will automatically come on whenever the front doors are opened and the run switch is in the "night run" or "night park" position. A switch easily accessible to the driver shall be provided to disable farebox light. TS -74 FARE COLLECTION Space and structural provisions shall be made for installation of currently available fare collection devices, which shall be as far forward as practicable. Location of the fare collection device shall not restrict traffic in the vestibule, including wheelchairs if a front door loading device is used, and shall allow the driver to easily reach the farebox controls and to view the fare register. The farebox shall not restrict access to the driver area, shall not restrict operation of driver controls and shall not—either by itself or in combination with stanchions, transfer mounting, cutting and punching equipment, or route destination signs—restrict the driver's field of view per SAE Recommended Practice J1050. The location and mounting of the fare collection device shall allow use, without restriction, by passengers. The farebox location shall permit accessibility to the vault for easy manual removal or attachment of suction devices. Meters and counters on the farebox shall be readable on a daily basis. The floor under the farebox shall be reinforced as necessary to provide a sturdy mounting platform and to prevent shaking of the farebox. Contractor shall provide fare collection installation layout to the Agencies for approval. Transfer mounting, cutting and punching equipment shall be located in a position convenient to the driver. Agency will specify a farebox for Contractor to install. TS -75 INTERIOR ACCESS PANELS AND DOORS Access for maintenance and replacement of equipment shall be provided by panels and doors that appear to be an integral part of the interior. Access doors shall be hinged with gas props or over -center springs, where practical, to hold the doors out of the mechanic's way. Panels shall prevent entry of mechanism lubricant into the coach interior. All fasteners that retain access panels shall be captive in the cover. TS 75.1 FLOOR PANELS Access openings in the floor shall be sealed to prevent entry of fumes and water into the coach interior. Flooring material at or around access openings shall be flush with the floor and shall be edge -bound with stainless steel or another material that is acceptable to the Agency to prevent the edges from coming loose. Access openings shall be asymmetrical so that reinstalled flooring shall be properly aligned. Fasteners shall tighten flush with the floor. The number of special fastener tools required for panel and access door fasteners shall be minimized. Section 5 – Page 92 VVTA Solicitation No. 2013-04 Rev 4 Dated WWU Passenger Accommodations TS -76 PASSENGER SEATING TS 76.1 ARRANGEMENTS AND SEAT STYLE Forward -Facing Seat Configuration Passenger seats shall be arranged in forward -facing configuration with a minimum of 55 reclining and cushioned passenger seats. Contractor to provide seat layout to the Agency once the Agency has provided the seat manufacturer and model number. Minimum 48 of seats with restroom option. Agencies to specify options such as rest room, cup holders, head rests, foot rests, etc. Prices for options should be quoted as separate line items. TS 76.2 HIP -TO -KNEE ROOM Hip -to -knee room measured from the center of the seating position, from the front of one seat back horizontally across the highest part of the seat to a vertical surface immediately in front, shall be a minimum of 26 in. At all seating positions in paired transverse seats immediately behind other seating positions, hip -to -knee room shall be no less than 27 in. TS 76.3 FOOT ROOM Foot room, measured at the floor forward from a point vertically below the front of the seat cushion, shall be no less than 14 in. Seats immediately behind the wheel housings and modesty panels may have foot room reduced. TS 76.4 AISLES The aisle between the seats shall be no less than 14 in. wide at seated passenger hip height. TS 76.5 STRUCTURE AND DESIGN Passenger seats shall be arranged in a transverse, forward -facing configuration. No more than 10 seated positions shall be lost on any coach configuration to accommodate two wheelchair passengers occupying the securement positions. Each transverse, forward -facing seat, except the rear seats, shall accommodate two adult passengers. Floor seat tracks shall be stainless steel and shall be welded to the coach frame and be nearly flush with the finished floor. The wall tracks shall be stainless steel or aluminum and shall be bolted or riveted to the sidewall. Seats shall be commuter coach reclining seats. Seat frames shall be constructed of high-strength, fatigue -resistant, welded steel with a durable powder -coated, corrosion -resistant colored finish that Section 5 — Page 93 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 complements the coach interior. The seat frame shall be wall mounted with heavy gauge steel brackets and shall be attached to the coach floor with a heavy duty stainless steel T pedestal. The seat back shall recline 5 in. (127 mm) maximum with an infinite number of stops. The reclining seat backs shall be provided with a dress -up feature to facilitate coach cleaning. Seat width shall be nominal 40.50 in. (1029 mm). Aisle shall not be less than 14 in. (356 mm) wide. TS 76.6 CONSTRUCTION AND MATERIALS Seat cushions shall be supported by steel serpentine springs. Seat covering shall be Holdsworth, Lantal or similar high-quality wool fabric. Typical seat covering weight shall be 24 oz. (680 g)/sq. yd. Overall composition shall typically be 54 percent wool, 9 percent nylon and 37 percent cotton. Pile composition shall typically be 85 percent wool and 15 percent nylon. Backing composition shall typically be 100 percent cotton. Abrasion from a 28 oz. (794 g) loading shall not affect appearance with 60,000 rubs. The front face of the seat upright and side boxing of cushions shall be covered with Holdsworth, Lantal or other similar wool fabric to complement the seat cushion. Backrest fabric shall be rugged carpet material. Seat armrest shall be dark gray in color. Seat foam padding shall be polyurethane. Seat upholstery shall utilize zippers or Velcro that allows them be removed from the seat cushions for cleaning/replacement purposes. Agencies shall select seat fabric. TS 76.7.1 FRONT DOOR Forward of the front wheels and under direct observation of the driver. TS 76.8 MATERIALS AND CONSTRUCTION Structure of the doors, their attachments, inside and outside trim panels and any mechanism exposed to the elements shall be corrosion resistant. Door panel construction shall be of corrosion -resistant metal or reinforced non-metallic composite materials. When fully opened, the doors shall provide a firm support and shall not be damaged if used as an assist by passengers during ingress or egress. Door edges shall be sealed to prevent infiltration of exterior moisture, noise, dirt and air elements from entering the passenger compartment, to the maximum extent possible based on door types. The closing edge of each door panel shall have no less than 2 in. of soft weather stripping. The doors, when closed, shall be effectively sealed, and the hard surfaces of the doors shall be at least 4 in, apart (not applicable to single doors).The combined weather seal and window glazing elements of the front door shall not exceed 10 degrees of binocular obstruction of the driver's view through the closed door. Minimum doorway width per ADA requirements. TS 76.9 DOOR GLAZING The upper section of both front and rear doors shall be glazed for no less than 45 percent of the respective door opening area of each section. The lower section of the front door shall be glazed for no less than 25 percent of the door opening area of the section. Section 5 — Page 94 VVTA Solicitation No. 2013-04 Rcv _4Dated 129/1 Door glazing shall be easily replaceable TS 76.9.1 ACTUATOR The nominal door opening and closing speed shall be in the 3-5 second range. The maximum door opening and closing speeds will be regulated using fixed, maintenance free orifices and airline sizes. If required, door speeds can be decreased with the addition of a flow -restricting device. Actuators and the complete door mechanism shall be concealed from passengers but shall be easily accessible for servicing. TS 76.10 EMERGENCY OPERATION In the event of an emergency, it shall be possible to manually open doors designated as emergency exits from inside the coach using a force of no more than 25 lbs after actuating an unlocking device. The unlocking device shall be clearly marked as an emergency -only device and shall require two distinct actions to actuate. The respective door emergency unlocking device shall be accessible from the doorway area. The unlocking device shall be easily reset by the operator without special tools or opening the door mechanism enclosure. Doors that are required to be classified as "emergency exits" shall meet the requirements of FMVSS 217. TS 76.11 DOOR CONTROL The door control shall be located in the operator's area within the hand reach envelope described in SAE Recommended Practice J287, "Driver Hand Control Reach." The drivers door control shall provide tactile feedback to indicate commanded door position and resist inadvertent door actuation. TS 76.12 DOOR CONTROLLER Doors shall be operated by push-button controls, conveniently located and operable within the drivers reach. The push buttons shall be labeled. A control or valve in the operator's compartment shall shut off the power to, and/or dump the power from, the front door mechanism to permit manual operation of the front door with the coach shut down. TS -77 WHEELCHAIR LIFTS TS -77.1 LIFT A travel lift and two forward -facing mobility device securement areas shall be provided. The lift assembly shall comply with all current ADA and FMVSS 403 and 404 requirements. The lift shall be installed below the floor line at the number 2 right-hand luggage bay on the curbside of the coach. The lift shall be controlled by a dash -mounted toggle switch and a rear lift area toggle switch, and operated by up/down switches on a pendant mounted to the lift support bracket inside the number 2 baggage bay. The lift restraint belt must be buckled before the lift can be raised or lowered. The safety Section 5 — Page 95 VVTA Solicitation No. 2013-04 Rev 4 Dated 8(29/13 interlock circuit can be energized to operate the lift only if the transmission is in neutral, the park brake is applied, engine fast idle is on, the dash -mounted master switch is on, the lift secondary switch is on, and the lift restraint belt is buckled. The wheelchair loading system shall provide safe, comfortable and rapid ingress and egress for applicable passengers from the street level or a curb. When not in use, the lift shall stow in the luggage bay. The lift mechanism shall include a threshold warning device to provide "passenger on platform" information and to prevent stowing the lift platform when a passenger is sensed. The outer barrier shall be automatically controlled and shall be such that it cannot be overridden by the loading system operator. A dash -mounted indicator light shall be provided and shall be illuminated when the loading system is activated. The interlock shall apply, the coach shall not move and the engine throttle shall be disabled whenever the wheelchair loading system is activated. If the lift door is open or ajar, the interlock shall remain engaged. Brackets, clamps, screw heads and other fasteners used on the passenger assists shall be anodized aluminum or stainless steel and shall be flush with the surface and free of rough edges. The lift control mounted on the lift structure shall have push button up/down switches. The toggle electrical supply switch shall be located in close proximity to the controller. This toggle switch must be turned on prior to the lift operation. All lift control switches shall be permanently labeled. Decals shall not be permitted. The stow guard switch shall be red in color, and the stow/deploy switch shall be black in color. These switches shall be incorporated in a handheld pendant. The lift shall include a hinged platform to bridge the coach floor to the lift platform. The bridge shall be hinged and locked in an upward position to act as a barrier when the lift is in use. The bridge shall be hinged and locked in an upward position to act as a barrier when the lift is in use. The bridge shall also allow lift passenger ingress/egress easily from the platform. Lift travel speeds and lift operation shall be adjusted to the lift manufacturer's specifications upon completion of the lift installation in to each coach and before coach delivery. The individual handrails shall incorporate a visual aid to ensure that they are folded in the proper order. The lift shall include an emergency system in case of driver operation malfunction. Should an emergency situation occur, the lift operator shall release the push-button switch on the controller to immediately stop the lift cycle. The emergency hand pump handles and pump shall be located in an enclosed box at the rear wall of the number 1 right-hand luggage bay door. The handle shall be stored adjacent to the pump to allow immediate usage. TS -77.2 LIFT DOOR The lift door shall be a single leaf design that operates in a sliding track mounted both above and below the door leaf. The door shall open by sliding to the rear of the coach and shall remain on a horizontal plane throughout the opening and closing process. No pin -hinged doors shall be provided. The transmission must be in neutral and the parking brake activated for the lift to operate. The accelerator shall be automatically disabled and the fast idle system activated when either the lift master switch is turned on or the I'lft door is open in order to provide maximum safety and security. These features shall be wired to the lift master switch to allow activation only when the transmission is in neutral. The coach directional (hazard) lights will also flash on/off. After the lift operation is completed, the lift shall be Section 5 — Page 96 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 properly stored and secured, with the access door closed and the lift master switch at the dash in the "off" position in order to move the coach. The lift door shall have a window in line with the other passenger windows and shall not detract from the appearance of the coach. The door latch mechanism shall be located in the lower section of the door so that operators in the 5th percentile female range can operate the lift door. The lift storage door shall not block the visual observation to the lift assembly while utilizing the manual override mode of the lift. A lift door design consisting of a horizontally hinged lift platform egress door mounted within a vertical motion pantograph luggage door is a preferred design. TS 77.3 LIFT WIDTH The installation of the lift to the coach structure as well as the installation of the lift door into the sidewall of the coach shall not affect the structural integrity of the coach. The parcel rack module above the wheelchair lift platform area shall be permanently removed to provide additional headroom. The modified rack shall be professionally finished at all ends. A threshold warning module with a red warning light and an acoustic sensor shall be mounted in the ceiling structure above the wheelchair lift entrance doorway. The heating and air ducts shall be rerouted around the lift area to ensure proper interior air conditioning/heating airflow and distribution. A passenger chime tape switch shall be mounted on the sidewall at the two wheelchair securement positions. Each coach shall have adequate information decals installed that detail the proper lift operation in both the normal and manual modes of operation. TS -77.4 LIGHTING REQUIREMENTS Lighting for the lift areas shall be designed to meet Title 13 and ADA and FMVSS 404 standards. Lighting shall be provided to effectively illuminate the lift area. Light shall be wired through the lift master toggle switch on the drivers dash and shall automatically illuminate when this switch is in the "on" position. The lighting design shall minimize the effect of glare on passengers entering the coach through the wheelchair lift door. During lift operation, the street surface shall be illuminated to a minimum of 6 candlepower a distance of 3 ft beyond the external dimensions of the lift platform once deployed and lowered. Additional lighting shall be provided to ensure illumination of the instruction placard and the manual override pump when it is in use. TS -77.5 SECUREMENT SYSTEM The vehicle interior shall permit the securement of two forward -facing wheelchair passengers in which the primary position shall be on the street side of the coach directly across from the lift. Securement areas shall be a minimum 30 x 48 in. as required by the ADA. Section 5 — Page 97 VVTA Solicitation No. 2013-04 Rev 4 Dated 9/29/13 A separate three-point belt securement shall be provided to effectively secure wheelchair passengers. To further secure the passenger during the lift operation, a retractable seat belt strap shall be provided at the ingress/egress area of the lift platform. A minimum 10.5 in. high barrier shall also be provided at the rear of the lift area for additional passenger protection. TS -77.6 ROOF VENTILATION/ESCAPE HATCHES Two roof ventilators shall be provided and designed to perform as escape hatches. One ventilator/escape hatch shall be located in the roof at the front of the coach, another in the roof at the rear of the coach. SIGNAGE AND COMMUNICATION TS -78 DESTINATION SIGNS A destination sign system shall be furnished on the front, and on the right side near the front door. Dash and rear sign should be an available option if requested by an agency. Contractor to provide list of optional signs to be used. All signs shall be controlled via a single human -machine interface (HMI). In the absence of a single mobile data terminal (MDT), the HMI shall be conveniently located for the coach driver within reach of the seated driver. A heavy-duty "stop request" signal button shall be installed at every seat location except the rear cross seat. TS -78.2 SIGNAL CHIME COMMUTER COACH A single "stop requested" chime shall sound when the system is first activated. A double chime shall sound anytime the system is activated from wheelchair passenger areas. Exit signals located in the wheelchair passenger area shall be no higher than 4 ft above the floor. Instructions shall be provided to clearly indicate the function and operation of these signals. TS -79 COMMUNICATIONS TS -79.1 CAMERA SURVEILLANCE SYSTEM Provide all wiring and mounting locations for a multi -camera surveillance system for the later provision of and installation of cameras, recorder, microphone, etc. The Procuring Agency to specify the camera system cable to be installed, the locations for pre -wiring and the quantity. Section 5 — Page 98 V VTA Solicitation No. 2013-04 Rev 4 Dated 81'29/13 TS -79.2 PUBLIC ADDRESS SYSTEM A public address system shall be provided on each coach for facilitating radio system and driver - originated announcements to passengers. TS -79.3 SPEAKERS Sufficient interior loudspeakers shall be provided, semi -flush mounted, on alternate sides of the coach passenger compartment, installed with proper phasing. Total impedance seen at the input connecting end shall be 8 Ohms. Mounting shall be accomplished with riv-nuts and machine screws. TS -79.4 AUTOMATIC PASSENGER COUNTER (APC) An APC system shall be available as an option and priced as a line item. Agency to provide details of APC system, including installation locations and number of coaches to be equipped. TS -79.5 RADIO HANDSET AND CONTROL SYSTEM TS -79.6 DRIVER'S SPEAKER Each coach shall have a recessed speaker in the ceiling panel above the driver. This speaker shall be the same component used for the speakers in the passenger compartment. It shall have 8 Ohms of impedance. TS -79.7 HANDSET Contractor will install a handset for driver use. TS -79.8 DRIVER DISPLAY UNIT (DDU) Contractor shall install a driver display unit as close to the driver's instrument panel as possible. TS -79.9 EMERGENCY ALARM Contractor shall install an emergency alarm that is accessible to the driver but hidden from view. END TECHNICAL PERFORMANCE SECTION Section 5 — Page 99 VVTA Solicitation No. 2013-04 Rev 4 Dated KW13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 -PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. ReuterC@mcicoach.com p,11=3177T.TFITIV. M. 1;T7-=UTMVRT M-1 Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 PROPOSED DELIVERY SCHEDULE clarifies that our proposal is based on the following delivery schedule and engine cooling package availability. 15 LED Coaches (Cummins ISX Diesel) with belt driven cooling system. 10 CNG Coaches (Cummins ISXG) with belt driven cooling system. CNG Coaches (Cummins ISXG) with electric fan drive cooling LED Coaches (Cummins ISX Diesel) with electric fan drive cooling Delivered 12 months ARO (after receipt of order) Delivered by June 30th 2015 or 12 months ARD whichever is later Delivered by September 30`h 2015 or 12 month! ARO whichever is later Delivered by December 31`h 2015 or 12 months ARO whichever is later does not currently have an available option for an electrically driven engine cooling fan released for production for either an ISX diesel engine. Contributing to this is the fact that Cummins has not released amounting location for an alternator of sufficient size on the ISX 9e to drive an electric cooling fan system. MCI's engineering work for the ISX engine to incorporate an electric cooling fan will not be pleted until Q1 2015 and further we do not have a definitive release date from Cummins for the larger alternator. In the event a suitable nator is not available in this application, MCI proposes to provide the ISX diesel or ISXG with its standard, belt driven cooling package. should be noted that MCI has gathered fuel economy data in conjunction with our cooling system partners that indicates limited to no fuel :onomv benefits with an electric cooling fan in an MCI Commuter coach equipped with a Cummins ISL engine. This is due to the fact that M not have a hydraulic drive cooling system but instead a direct belt driven system which has a low parasitic draw. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/ 1.1.5.17FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address• Mark Reuteramcicoach.com Number: Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 wishes to advise that the Departure angle of our coach is 6.2 degrees in lieu of the 8.6 deg (min) requested in the bid. the departure angle would require a complete redesign of our coach which is not feasible. Section 1 — Page 45 WTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 FORM FOR PROPOSAL DEVIATION 1.1.5.17 CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding' (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark Reuter cr.mcicoach.com Number: Proposer: Motor Coach Industries Inc. Phone Number: 847-285-2105 Detailed D scriotion of Reauested Deviation: The operating range of the CNG coach shall be at least 400 miles with an initial gas -settled pressure of 3600 psi at Wft." )ue to various factors such as road grades, duty cycles and driver's profiles the operating range of 400 miles may or may not believes that 400 miles may be achievable however as mentioned due to various factors such as road grades, duty cycles driver's profiles the operating range of 400 miles cannot be assured. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding' (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address- Mark. ReuterQmcicoach.com _ Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 Detailed Description of Requested Deviation: ACI's proposal is based on providing long life coolant and therefore, supplemental coolant additives are not required. coolant additives are not required with long life coolant Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 FORM FOR PROPOSAL DEVIATION 1.1.5.17 CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address Mark Reutef(@mcicoach.Com _ Proposer. Motor Coach Industries. Inc. Phone Number: 847-285-2105 Section: Detailed Description of Reauested Deviation: MCI's proposal is based on providing an engine brake for the ISX Diesel engine and a Transmission retarder for the ISL CNG ,ngine. retarder cannot be provided with the ISX Diesel engine due to space limitations of our current design Section 1 —Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 FORM FOR PROPOSAL DEVIATION 1.1.5.17 CERTIFICATION No. 7 - PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Reutera-mcicoach.com Number: I-:. 014= -,IT -1i arvrn ., Proposer: Motor Coach Industries. Inc. Phone Number: 847-285-2105 CNG lines shall be pressure tested to a minimum of 125 percent of system working pressure prior to fueling." to 125 percent of high pressure CNG lines is done by the supplier prior to shipment of components to MCI installation MCI pressure tests the fueling lines to 3225 psig. o Comply with MCI's standard process Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 -PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Reuterta)mcicoach.com Number: Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 Section: ACI's proposal is based on providing an aluminum fuel tank with 182 US GAL at 95% of capacity, includes baffles, 3/8 NPT drain Aug on lower side of the tank. As a result of the current fuel tank design, the fuel filler neck is not removable Rationale (Pros and Consl: 'lease refer to item N supporting documentation in our technical proposal for complete details on our proposed aluminum fuel tank Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 FORM FOR PROPOSAL DEVIATION 1.1.5.17 CERTIFICATION No. 7 -PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address• Mark Reuter(amcicoach.com Number: ong IT I • .� . gm M, •r Proposer: Motor Coach Industries. Inc. Phone Number: 847-285-2105 wishes to clarify that the CNG cylinders are mounted in the baggage bays of the coach and not on the roof. r. M ce refer to item N supporting documentation in our technical proposal for complete details on our proposed tank installation Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark Reuter@mciCOach.COm Number. Proposer: Motor Coach Industries Inc. Phone Number: 847-285-2105 MCI wishes to clarify that this requirement is specific to a Transit coach which does not utilize under floor baggage .ompartments. As a result, MCI's proposal is based on deletion of this requirement as it is no applicable for an over the road commuter coach. testing is not applicable to an over the road commuter coach. Section 1 - Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 FORM FOR PROPOSAL DEVIATION 1.1.5.17 CERTIFICATION No. 7 -PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in 'Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Re uterCa?mcicoach.com Number: Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 Detailed Description of Reauested Deviation: MCI would like to clarify that the floor at the stepwell area and the aisle (with the exception of the entrance ramp) is horizontal nd would not contain a slope. standard design and a redesign of our entrance area and stepwell area is not feasible. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 FORM FOR PROPOSAL DEVIATION 1.1.5.17 CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Reuter(a.mcicoach.com Number: Proposer: Motor Coach Industries. Inc. Phone Number: 847-285-2105 proposal is based on providing our standard steering column tilt of 21 degrees in lieu of 40 degrees. Rationale (Pros and Consl: rhe 21 degree tilt is based on the orientation of the driver's area and driver's seat. The 21 degree tilt is more applicable to an aver the road commuter coach. Additionally, modification to 40 degrees cannot be accommodated or would not be practical this type of vehicle. Section 1 — Page 45 WTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding' (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3-5). Deviation Number: 12 Email Address: Mark Reuter(a)mcicoach.com Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 MCI's proposal is based on providing the following: Ainimum Telescopic Height Adjustment Maximum Telescopic Height Adjustment of Slope Height Angle of Slope Height deg 32.12 in 0 deg 34 in deg 32 in 7 deg 33 in 4 deg 31 in 14 deg 32.5 in 1 deg 30 in 21 deg 32 in *. .I._ .� above telescopic configuration is standard equipment and provided on all MCI commuter coaches. Redisign of our steering am is not feasible and cannot be accommodated. Section 1 — Page 45 WTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 FORM FOR PROPOSAL DEVIATION 1.1.5.17 CERTIFICATION No. 7 - PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any pricelcost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address Mark Reuter9- mcicoach.com Number: Proposer. Motor Coach Industries, Inc. Phone Number: 847-285-2105 wishes to clarify that the Heating, ventilation and air conditioning (HVAC) system as well as the diagnostics will be municated through the Powertrain Level in lieu of the Multiplex Level. Rationale (Pros and Consl: MCI's air conditioning diagnostics is communicated through the powertrain system and not the multiplex system. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 FORM FOR PROPOSAL DEVIATION 1.1.5.17 CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Reuteraamcicoach.com _ Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 Section: 's proposal is based on providing the 10 percent excess wires for spares as requested with the exception of the harness at front cap and the parcel rack areas. Rationale (Pros and Consl: 0 percent spares are not provided in the front cap and parcel rack areas due to space limitations in these areas. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 -PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark Reuteramcicoach.com Number: in. 1=TMTT-1 Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 's wishes to clarify that the parcel rack blowers and the motor in the driver's HVAC unit are permanent magnet motors in of brushless type motors. Evaporator and Condenser motors are brushless. does not have approved brushless motors for the driver's HVAC and parcel rack blowers. Significant testing would be aired once an approved motor becomes available to ensure performance parameters are not affected. As a result our iosal is based on providing brush type motors in these areas. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev _A --Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any pricelcost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any pricelcost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address- Mark. Reuter0mcicoach.com Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 Section: proposal will be based on providing our standard instruments and alarms (see attached) which includes the following: Engine Run, Rear does not have an Amber light HVAC control unit is located at the right side of the dash on the HVAC control panel - Driver's defrost and ventilation combined switch is located at the right side of dash on HVAC control panel - The single wiper/washer switch is located at left side of steering column - Dash panel light will be the dimmer switch using the digital signal through the Mux system Interior light switch will be located at the left hand dash switch panel - Fast idle switch will be located at the left hand dash switch panel - WC ramp/kneel enable, Front door ramp/kneel enable and Front door ramp do not apply to MCI's coach refer to the attached diagram for complete Interior layout of our proposed commuter coach. our existing dash area for this procurement is not feasible. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address Mark Reuter anmcicoach.com Number: Proposer: Motor Coach Industries. Inc. Phone Number: 847-285-2105 :.MCI proposal will be based on providing our standard instruments and alarms which includes the following: - Video system event switch —specification calls for provisions only and would not include this switch - Passenger door control — is a three position momentary switch - Rear Door override — not applicable to MCI's coach - Fire Suppression — located at rear of driver LH console at 8 post - Mobile Data Terminal — Clarification of this device is needed to determine mounting - Low Profile Microphone — Clarification needed - Hill Holder — Not available and cannot be provided - Master Door/Interlock — Not available and cannot be provided. To bypass entrance door switch a dump valve is under dash. girl ..._nir refer to the attached diagram for complete Interior layout of our proposed commuter coach. our existing dash area for this procurement is not feasible. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Reuterl?o mcicoach.com 01-Irli r7i 11T=- a.=. JILTT-w-mm I•, Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 Section: t. MCI proposal will be based on providing our standard instruments and alarms which includes the following: Warning Interlocks Deactivated —Not available and cannot be provided Retarder Disable— switch and red light are not available, however, a retarder enable and amber light will be provided Rear Door passenger Sensor Disable — Not available on MCI coaches Door Obstruction — Not available on MCI coaches Door Ajar— Not available on MCI coaches Methane Detection —Solid red at 20% and above Turntable — Not available on MCI coaches refer to the attached diagram for complete Interior layout of our proposed commuter coach. our existing dash area for this procurement is not feasible. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark Reuter(o7mcicoach.com • . C . •r --T-11 Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 MCI's proposal will be based on providing our standard windshield wiper design that are electric motor driven with two speeds nd single speed intermittent wiper action. Rationale (Pros and Consl: MCI'S current design and a resign of our wiper system would be cost prohibitive. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129113 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: 20 Email Address: Mark. Reuter(Wmcicoach.com Number: Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 proposal will be based on providing R134 Freon which is the Freon currently used on all MCI coach models. additionally, the air conditioning system is capable of reducing the passenger compartment temperature from 110 to 75 + or - 3 in 30 minutes. unlike a transit coach the MCI commuter coach is provided with parcel rack air conditioning vents which allow oning to be provided directly on to the passenger immediately after coach start up. Rationale (Pros and Consl: MCI'S proposal is based on providing R134 Freon. Should R407 become mandatory during the 5 year contract MCI will comply with this requirement. However, additional testing of R407 would be required to determine the applicable air conditioning pull down parameters. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Reuter mcicoach.com Proposer: Motor Coach Industries. Inc. Phone Number: 847-285-2105 VICI requests approval to provide our standard energy absorbing front bumper assembly, nominally 20 inches high, which .onsists of three energy absorbing modules that are self -restoring black urethane with minimum 1700 psi tensile strength, 250! elongation, and 350 psi tear strength. The hollow ribbed black urethane cover has excellent resistance to tears, abrasion, salt, iydro-carbons, detergents, sunlight, and is repairable. An inner support structure constructed of aluminum or high strength steel provides a single, full length structural support for the bumper module. The bumper assembly shall be hinged at the )ottom for access to the spare tire, with the bumper release lever located at the top of the front roadside service compartmen, •r, . ,r•. proposal is based on providing our standard front energy absorbing bumper as described above. Redesigning our front er is not practical and would be cost prohibitive. Section 1 — Page 45 VVTA Solicitabon No. 2013-04 Rev 4 Dated 8129/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 -PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any pricelcost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address, Mark Reuter@mcicOach.COm _ Proposer: Motor Coach Industries Inc. Phone Number: 847-285-2105 :I requests approval to provide our standard energy absorbing rear bumper which will be nominally 11 inches high consisting a rigid steel and aluminum inner support structure with a repairable hollow ribbed.black urethane cover. The bumper is aped to wrap around the coach rear corners to protect the engine compartment doors and also incorporates an anti -ride, or ening feature to prevent unauthorized riders. e damping system built into the bumper will operate on air at atmospheric pressure to absorb and dissipate impact forces plied to the bumper in the event of a minor collision. The outer bumper cover will have excellent resistance to tears, rasion, salt, hydro -carbons, detergents, and sunlight. The complete assembly will be self-contained, self -restoring and YS proposal is based on providing our standard rear energy absorbing bumper as described above. Redesigning our rear mper is not practical and would be cost prohibitive. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8!29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any pricelcost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: 23 Email Address- Mark Reuteramcicoach. corn Proposer: Motor Coach Industries Inc. Phone Number: 847-285-2105 Section: 12ptoned Descrintion of Requested Deviation: vlCI wishes to clarify that the floor covering is joined at the sidewall and covered with a stainless steel heat duct. This istallation method ensures that the heat duct seals the flooring. Rationale (Pros and Cons): The above installation is based on our current design which has worked very successfully in the manufacture and delivery of over 10,000 commuter coaches. Section t — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specked in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address Mark Reutergmcicoach.com Proposer: Motor Coach Industries. Inc - Phone Number: 847-285-2105 Section: proposal is based on providing a minimum 2 foot-candle power measured on the step tread based on ADA requirements. Rationale (Pros and Cons): The above lighting was designed to comply with current ADA requirements. Section 1 — Page 45 WTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding' (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Reuter mcicoach.com Proposer: Motor Coach Industries Inc. Phone Number: 847-285-2105 Section: proposal is based on providing total impedance seen at the input connecting end of 4 ohm speakers in lieu of 8 ohms Is MCI's current speaker design. :••r rM•r t ohm speakers have lower impedance and therefore less resistance to electrical currents than 8 ohm speakers. Section 1 — Page 45 WTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 -PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding' (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: 26 Email Address: Mark Reuter aC)mcicoach.com Proposer: Motor Coach Industries. Inc._ Phone Number: 847-285-2105 Section: refer to MCI's optional quotation page included with our price proposal. Section 1 — Page 45 VVTA Solicitation No, 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in `Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. ReutercDmcicoach.com i- -. 1 a_ -, - ! -r Proposer: Motor Coach Industries. Inc. Phone Number: 847-285-2105 Section: ACI proposal is based on providing the driver's speaker located in the driver's modesty panel behind the driver. Also the peaker will have 4 ohms of impedance. speaker is located on the driver's modesty panel for optimal sound quality. Additionally, 4 ohm speakers have lower ice and therefore less resistance to electrical currents than 8 ohm speakers. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated M9113 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. VVTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any pricelcost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: 28 Email Address Mark Reute mmcicoach.com Proposer: Motor Coach Industries Inc. Phone Number: 847-285-2105 Section: proposal is based on providing our standard driver's display tell-tale cluster located on the front instrument panel as ed per request 4 Rationale (Pros and Cons): A redesign of MCPS standard tell -Tale cluster would be cost prohibitive. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated/2✓ 9/13 r�q Reliability Driven" ATTACHMENT # 2 REFERENCES AND NON PRICED INFORMATION 1.1.5.23 REFERENCE FORM CERTIFICATION No. 13 - PROPOSAL No. WTA- RFP 2013-04 Proposer by its signature below certifies that the following references for 45 -foot commuter coaches were sold to other clients over the last seven (7) years (use additional pages as necessary): Agency Name Contact Name/Phone Qty of New 45 -foot Coaches bought Year 1. Go Transit Mr. George Goulas 416-996-9211 2. Denver RTD Mr. Lou Ha 303-299-6265 3, New York City Mr. Bart Betz 347-643-5143 Transit 4. Golden Gate Mr. Steven Millar 415-257-4437 Bridge & Transportation District 5. City of Santa Mr. Adrian Augilar 661-295-6305 Cladta 6, Loudoun County Ms. Nancy Gourley 703-737-8384 7. PRTC Mr. Eric Marx 703-580-6117 Signature of the Proposer's Author' ad' icial Patrick Scully Executive Vice President Sales and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date 104 - D4500 Commuter Coaches, 2011-2013 54 - D4500 Commuter Coaches, 2013 54 - D4500 Commuter Coaches, 2012 32 - D4500 Commuter Coaches, 2011 6 - D4500 Commuter Coaches, 2013 2 - D4500 Commuter Coaches, 2013 5 - D4500 Commuter Coaches, 2012 Section 1 — Page 52 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29113 Reliability Driven` ATTACHMENT # 3 FORMS EXCLUDING PRICING AND WARRANTY INFORMATION 1.1.5.11 DEBARRED PROPOSERS CERTIFICATION CERTIFICATION No. 1 - PROPOSAL No. WTA RFP -2013-04 FTA CERTIFICATION REGARDING DEBARMENT, SUSPENSION, INELIGIBILITY AND VOLUNTARY EXCLUSION For Contracts and Subcontracts in Excess of $100,000 Instruction for Certification 1. By signing and submitting its bid or proposal, the prospective lower tier participant is providing the signed certification set out below. 2., The certification in this clause is a material representation of fact upon which reliance was placed when this transaction was entered into; If it is later determined that the prospective lower tier participant knowingly rendered an erroneous certification, in addition to other remedies available to the Federal Government, VVTA may pursue available remedies, including suspension and/or debarment. 3. The prospective lower tier participant shall provide immediate written notice to VVTA if at any time the prospective lower tier participant learns that its certification was erroneous when submitted or has become erroneous by reason of changed circumstances. 4. The terms 'covered transaction," "debarred," "suspended," "ineligible," 'lower tier covered transaction," "participant," "persons," "principal," "proposal," and "voluntary excluded," as used in this clause, have the meanings set out in the Definitions and Coverage sections of rules implementing Executive Order 12549 [49 C.F.R. Part 29]. You may contact VVTA for assistance in obtaining a copy of those regulations. 5. The prospective lower tier participant agrees by submitting its bid or proposal that, should the proposed covered transaction be entered into, it shall not knowingly enter into any lower tier covered transaction with a person who is debarred, suspended, declared ineligible, or voluntarily excluded from participation in this covered transaction, unless authorized in writing by VVTA. 6. The prospective lower tier participant further agrees by submitting its bid or proposal that it will include the clause, set out below, titled "Certification Regarding Debarment, Suspension, Ineligibility and Voluntary Exclusion — Lower Tier Covered Transaction," without modification, in all lower tier covered transactions. 7. A participant in a covered transaction may rely upon a certification of a prospective participant in a lower tier covered transaction that it is not debarred, suspended, ineligible, or voluntary excluded from the covered transaction, unless it knows that the certification is erroneous. A participant may decide the method and frequency by which it determines the eligibility of its principals. Each participant may, but is not required to, check the Non -procurement List issued by U.S. General Service Administration. Section 1 — Page 38 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 8. Nothing contained in the foregoing shall be construed to require establishment of system of records in order to render in good faith the certification required by this clause. The knowledge and information of a participant is not required to exceed that which is normally possessed by a prudent person in the ordinary course of business dealings. 9. Except for transactions authorized under Paragraph 5 of these instructions, if a participant in a covered transaction knowingly enters into a lower tier covered transaction with a person who is suspended, debarred, ineligible, or voluntarily excluded from participation in this transaction, in addition to all remedies available to the Federal Government, WTA and the other named procuring agencies may pursue available remedies including suspension and/or debarment. "Certification Regarding Debarment, Suspension Ineligibility and Voluntary Exclusion — Lower Tier covered Transaction" 1. The prospective lower tier participant certifies, by submission of its bid or proposal, that neither it nor it's "principals" [as defined at 49 C.F.R. §29.105(p) is presently debarred, suspended, proposed for debarment, declared ineligible, or voluntarily excluded from participation in this transaction by any Federal department or agency. 2. When the prospective lower tier participant is unable to certify to the statement in this certification, suchpective(p`aarticipant shall attach an explanation to its bid or proposal. /7 Signature of the Proposer's Aupfb—riz�4 Official Patrick Scully Executive Vice President Sales and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date Section 1 — Page 39 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29113 1.1.5.12 FTA CERTIFICATION OF RESTRICTIONS ON LOBBYING (For Proposals over $100,000) CERTIFICATION No. 2 - PROPOSAL No. WTA RFP 2013-04 I, Patrick Scully , hereby certify on behalf of Motor Coach Industries, Inc.(Company Name) that: 1. No Federal or State appropriated funds have been paid or will be paid, by or on behalf of the undersigned, to any person for influencing or attempting to influence an officer or employee of any State or Federal agency, a Member of the State Legislature or the United States Congress, an officer or employee of the Legislature or Congress, or an employee of a Member of the Legislature or the Congress, in connection with the awarding of any State of Federal contract, the making of any State or Federal grant, the making of any State or Federal loan, the entering into of any State or Federal cooperative agreement and the extension, continuation, renewal, amendment or modification of any State or Federal contract, grant, loan, or cooperative agreement. 2. If any funds other than Federal appropriated funds have been paid or will be paid to any person for influencing or attempting to influence an officer or employee of any Federal agency, a Member of Congress, or an officer or employee of Congress, in connection with this contract, grant, loan or cooperative agreement, which is funded in whole or in part by Federal funds, the undersigned shall complete and submit Standard Form LLL, "Disclosure Form to Report Lobbying," Approved pursuant to 31 U.S.C. 1352 0348-0046, in accordance with its instructions. 3. The undersigned shall require that the language of this certification be included in the award documents for any subcontractor at any tier performing work under this Federal -Aid funded Contract and that all subcontractors of any tier shall certify and disclose accordingly. This certification is a material representation of fact upon which reliance is placed when this transaction was made or entered into. Submission of this certification is a prerequisite for making or entering into this transaction imposed by § 13 52, Title 31, U.S. Code. Any person who fails to file the required certification shall be subject to a civil penalty of not less than $10,000 and not more than $100,000 for each such failure. day of October 2013. Signature of the Proposer's ulho!Yed Official Patrick Scully Executive Vice Pre'§Ment Sales and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date Section 1 — Page 40 VVTA Solicitation No. 2013-04 Rev 4 _Dated 8/29/13 1.1.5.13 DBE APPROVAL CERTIFICATION CERTIFICATION No. 3 - PROPOSAL NO. VVTA-RFP 2013-04 I hereby certify that the Proposer has complied with the requirements of 49 C.F.R. Part 26, Participation by Disadvantaged Business Enterprises in DOT Programs by submitting an annual DBE goal to the Federal Transit Administration, and that its goals have either been approved or have not been disapproved b the Federal Transit Administration. 1 Signature of the Proposer's AuthOlIzed Ifficial Patrick Scully Executive Vice President Sales and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date Section 1 — Page 41 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.14 CERTIFICATE OF COMPLIANCE WITH COACHES TESTING REQUIREMENT CERTIFICATION No. 4 - PROPOSAL No. VVTA-RFP 2013-04 The undersigned certifies that the vehicle offered in this procurement complies and will, when delivered, comply with 49 U.S.C. § 5323 © and FTA's implementing regulation at 49 C.F.R. Part 665 according to the indicated one of the following three alternatives. (Mark one and only one of the three blank spaces with an 'Y') L The Coaches offered herewith have been tested in accordance with 49 C.F.R. Part 665 on the vehicles being sold should have the identical configuration and major components as the vehicle in the test report, which must be submitted with this Offer. If the configuration or components are not identical, the manufacturer shall provide with its Offer a description of the change and the manufacturer's basis for concluding that it is not a major change requiring additional testing. IN The manufacturer represents that the vehicle is "grandfathered" (has been used in mass transit service in the United States before October 1, 1988, and is currently being produced without a major change in configuration or components), and submits with this Offer the name and address of the recipient of such a vehicle and the details of that vehicle's configuration and major components. The vehicle is a new model and will be tested and the results will be submitted to Lead Procuring Agency prior to acceptance of the first Coaches. The undersigned understands that misrepresenting the testing status of a vehicle acquired with Federal financial assistance may subject the undersigned to civil penalties as outlined in the Department of Transportation's regulation on Program Fraud Civil Remedies, 49 C.F.R. Part 31. In addition, the undersigned un nds that FTA may suspend or debar a manufacturer under the procedures in 49 C.F.R. Part1 Signature of the Propos r s Author O ial Patrick Scully Executive Vice President Sales and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date Section 1 — Page 42 VVTA solicitation No 2013-04 Rev 4 Dated 8/29113 1.1.5.15 FEDERAL MOTOR VEHICLE SAFETY STANDARDS CERTIFICATION No. 5 - PROPOSAL No. WTA-RFP 2013-04 The Proposer hereby certifies that the following statement is true and correct (select one option): N The vehicle(s) to be supplied is in compliance with the Federal Motor Vehicle Safety Standards issued by the National Highway Traffic Safety Administration in 49 C.F.R. Part 571. The vehicle(s) to be supplied is not subject to the Federal Motor Vehicle Safety Standards issued by the National Highway Traffic Safety Administration in 49 C.F.R. Part 571. I The vehicle(s) to be supplied is subject to the Federal Motor Vehicle Safety Standards issued by the National Highway Traffic Safety Administration in 49 C.F.R. Part 571 but no FMVSS certification is available at this time because the vehicle is a new model (Federal Register Vol. 56, No. 185, page 48391, September 24, 1991). Patrick Scully Executive Vice President Sales and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date Section 1 — Page 43 WTA Solicitation No. 2013-04 Rev 4 Dated 829113 1.1.5.18 PROPOSER SERVICE AND PARTS SUPPORT DATA CERTIFICATION No. 8 - PROPOSAL No. VVTA- RFP 2013-04 Location of most Responsive Technical Service Representative to Lead Procuring Agency Name Address David Bugenig Telephone 530-945-9824 Proposer to describe technical services readily available from said representative. Location of most Responsive Parts Distribution Center to Lead Procuring Agency Name MCI Service Parts, Inc. Address 7001 Universal Coach Drive, Louisville, KY 40258 Telephone 1-800-323-1290 Proposer shall describe the extent of parts available at said center. Policy for Delivery of Parts and Components to be Purchased for Service and Maintenance Regular Method of Timely Shipment Cost to Lead Procuring Agency Motor Coach Industries, Inc. Company Name October 31, 2013 Date Only overnight shipments are charged Section 1 — Page 46 WTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.19 BUY AMERICA CERTIFICATION — COACHES CERTIFICATION No. 9 - PROPOSAL No. WTA- RFP 2013-04 Rolling Stock Note. Complete either Alternative A or B ALTERNATIVE A CERTIFICATE OF COMPLIANCE WITH 49 U.S.C. 65323(i)(2)(C) [Former Section 165(b)(3)] The Proposer hereby certifies that it will comply with the requirements of 49 U.S.C. §53230)(2)(C) and the aoolic ere ulatiopsfi 49 C.F.R. 6 661.11. of the Proposer'p`Authorijed Official Patrick Scully Executive Vice President Sales and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date ALTERNATIVE B CERTIFICATE OF NON-COMPLIANCE WITH 49 U.S.C. 65323(i)(2Xc) [Former Section 165(b)(3)] The Proposer hereby certifies that it will not comply with the requirements of 49 U.S.C. §53230)(2)(C), but it may qualify for an exception pursuant to 49 U.S.C. §53230X2)(6), or (D) and regulations in 49 C.F.R. § 661.7. Signature of the Proposer's Authorized Official Name and Title of the Proposer's Authorized Official Company Name Date Section 1 — Page 47 VV`rA Solicitation No. 2013-04 Rev 4 Dated 8129/13 1.1.5.20 BUY AMERICA CERTIFICATION — SPARE PARTS CERTIFICATION No. 10 - PROPOSAL No. WTA- RFP 2013-04 Steel, Iron and Manufactured Products Note: Complete either Alternative A or B ALTERNATIVE A CERTIFICATE OF COMPLIANCE WITH 49 U.S.C. §5323(1)(1) [Former Section 165 (a)] The Proposer hereby certifies that it will comply with the requirements of 49 U.S.C. §5323(j)(1) and the applicable regulations in 49 C.F.R. part 661. Signature of the Proposer's Authorized Official Name and Title of the Proposer's Authorized Official Company Name Date ALTERNATIVE B CERTIFICATE OF NON-COMPLIANCE WITH 49 U.S.C. §53230)(1) [Former Section 165(a) The Proposer hereby certifies that it cannot comply with the requirements of 49 U.S.C. §53230)(1), but it may qualify for an exception pursuant to 49 U.S.C. §53230x2)(B), or (D) and regulations in 49 C.F.R. §661.7/1 /- Signature of the Proposer'sthonzed fficial Patrick Scully Executive Vice Pr ales and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date Section 1 — Page 46 WTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 BUY AMERICA LAW 49 U.S.C. §53230) BUY AMERICA STIPULATIONS: "(1) The Secretary of Transportation may obligate an amount that may be appropriated to carry out this chapter for a project only if steel, iron, and manufactured goods used in the project are produced in the United States. "(2) The Secretary of Transportation may waive paragraph (1) of this subsection if the Secretary finds that — "(A) applying paragraph (1) would be inconsistent with the public interest; "(B) the steel, iron, and goods produced in the United States are not produced in sufficient and reasonably available amount or are not of a satisfactory quality; "(C) when procuring rolling stock (including train control, communication and traction power equipment) under this chapter — "(i) the cost of components and subcomponents produced in the United States is more than 60 percent of the cost of all components of the rolling stock; and "(ii) final assembly of the rolling stock has occurred in the United States; or "(D) including domestic material will increase the cost of the overall project by more than 25 percent. "(3) In this subsection, labor costs involved in the final assembly are not included in calculating the cost of components" Section 1 — Page 49 VVTA Solicitation No. 2013-04 Rev 4 Dated/6 29/13 1.1.5.21 INTEREST AND GRATUITIES FORM CERTIFICATION No. 11 - PROPOSAL No. VVTA- RFP 2013-04 Proposer by its signature below, certifies that except as disclosed below, Proposer, its officers, employees and their immediate families have not offered or given a gratuity in any form including, without limitations, entertainment, favors, loans, gifts or anything of greater than nominal value for any reason including personal, non -business related reasons to any VVTA officer or employee or their immediate families within the preceding twelve (12) months. For the purpose of this section, nominal value means anything: (1) having an aggregate value of $35.00 (thirty-five dollars), or less per year, or (2), any perishable item (flowers or food) of any value, except that prepared meals are subject to the $35.00 limit. A campaign contribution is not a gratuity and is not the subject of this Certification. Proposer further certifies that except as disclosed below, Proposer, its officers, employees and their immediate families presently have no interest nor within the preceding twelve (12) months had any interest including, without limitation, any business or personal relationship that would appear to conflict with the performance of services required to be performed under this Contract. Disclosable interests and relationships are those that may reasonably be viewed as creating a potential or actual conflict of interest. Signature of the Proposer's Authorized Patrick Scully Executive Vice President Sales and Service Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date Section 1 — Page 50 VVTA Solicitation No. 2013-04 Rev 4 Dated /29113 1.1.5.24 ACKNOWLEDGEMENT OF ADDENDUM CERTIFICATION No. 14 - PROPOSAL No. VVTA- RFP 2013-04 The following form shall be completed and included in the price proposal. Failure to acknowledge receipt of all addenda may cause the proposal to be considered non-responsive to the solicitation. Acknowledged receipt of each addendum must be clearly established and included with the Offer. The undersigned Proposer acknowledges receipt of the following addendum to the documents: Addendum No. 1 Date. October 7, 2013 Addendum No. 2 Date: October 22, 2013 Addendum No. Date: Addendum No. Date: Addendum No. Date: Addendum No. Date: Signature of the Patrick Scully Executive Vice Presiftr+6les and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date Section 1 — Page 53 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 e Reliability Driven - ATTACHMENT # 4 SUPPORTING DATA TECHNICAL PROPOSAL AND PRODUCT EVALUATION ITEMS A THRU P Reliability Driven - ATTACHMENT A VEHICLE CONSTRUCTION Reliability Driven" MATERIALS AND CONSTRUCTION For economy in maintenance, it is essential that parts and units be arranged so that rapid assembly and disassembly will be possible for the coach being provided. The dimensions of all parts, unless particularly specified, will be in accordance with current standards of the Society of Automotive Engineers, or the metric equivalents. All units or parts not specified shall he Manufacturer's standard units or parts and shall conform in material, design and workmanship to industry standards and shall meet or exceed all Federal and State motor vehicle safety standards. During the manufacturing of the coaches all parts shall be new and in no case will used, reconditioned or obsolete parts be accepted. No advantages shall be taken by the Manufacturer in the omission of any parts or details that make the coach complete and ready for service, even though such parts or details are not mentioned in these specifications. Workmanship throughout shall conform to the high standard of commercially accepted practice for the class of work and shall result in a neat and finished appearance. All exposed surfaces and edges shall be smooth, free from burrs and other projections, and shall be neatly finished. Exposed metal surfaces, prior to paneling or covering shall be properly prepared and coated with protective material to insure against corrosion or deterioration. All lubrication points, unless otherwise specified, shall be capable of accepting a high pressure grease gun operated on fittings that permit grease to travel into the lubrication point but does not permit the grease to escape and designed so that when the grease gun is withdrawn, there is a positive barrier preventing dirt from entering the fitting. These fittings shall be of one manufacture and shall be accessible for a grease gun while the vehicle is being serviced on either a lift or a pit. BODY DESIGN The coach shall have a clean, smooth, simple design, primarily derived from coach performance requirements and passenger service criteria. Body construction shall not be of a body on chassis type. The exterior and body features, including grilles and louvers, shall be shaped to allow complete and easy cleaning by automatic bus washers without snagging washer brushes. The retention of water and dirt in or on any body feature or the freezing or bleeding out of this dirt and water after leaving the washer shall be minimized. Body and windows shall be sealed to prevent leaking of air, dust, or water under normal operating conditions and during cleaning in automatic bus washers for the service life of the coach. Accumulation of spray and splash on any window of the coach generated by its wheels on a wet road shall be minimized. The undercarriage of the coach shall be sealed off to the maximum extent practicable to signiflcantly reduce the intrusion of road spray. MATERIALS Body materials shall be selected and the body fabricated to reduce maintenance, extend durability, and provide consistency of appearance throughout the life of the coach. Detailing shall be kept simple; add-on devices and trim shall be minimized and, where necessary, integrated into the basic design. The coach shall resist corrosion from atmospheric conditions and road salts. It shall maintain structural integrity and nearly maintain original appearance throughout its service life, provided it is maintained in accordance with the procedures specified in the service manual. All exposed body panels above and below the floor line shall be aluminum or stainless steel except for the front end upper and lower panels, the rear end upper panels and the upper sidewall panel which are made of fiberglass or galvanized steel. Materials exposed to the elements and all joints and connections of dissimilar metals shall be corrosion -resistant and shall be protected from galvanic corrosion. All frame members below the passenger floor that are subject to road splash and are less than 0.06 inch (1.5 mm) shall be stainless steel for maximum corrosion protection. All other frame members exposed to splash are to be High Strength Low Alloy steel and are to be 0.06 inch (1.5 mm) thick minimum and shall be coated with Tectyl undercoating or approved equal, on all surfaces exposed to road splash for maximum corrosion protection. Floor supports in the passenger and drivers area, the sidewall structures and roof structures that are not exposed to road spray shall be High Strength Low Alloy and primed prior to incorporation into the coach assembly. Outer sidewall panels above the passenger floor and below the windows shall be galvanized steel, pre -primed. The roof panels shall be pre -primed aluminum both sides and the front and rear roof caps fiberglass. The upper rear engine door and louvers may be fiberglass panels mounted to stainless steel frames with powder coated aluminum screens. The upper side comer panels may be fiberglass with powder coated aluminum screens. The upper wheelchair lift door may be made of an aluminum frame or other acceptable lightweight material and aluminum exterior panel. Non-structural underbody panels used for baggage bay floors and to retain insulation in other areas, shall be Tectyl or approved equal undercoated aluminum or stainless steel for maximum corrosion protection. In the wheel well areas, non-structural closeout panels shall be stainless steel. Before assembling, all metal body parts must be given a thorough anti -corrosion treatment. Joints between dissimilar metals shall be properly insulated with an inert plastic tape to avoid corrosion due to electrolytic action. All nuts, bolts, clips, washers, clamps, and like parts shall be zinc plated, phosphate coated, black oxide coated, stainless steel, or nylon to prevent corrosion. All exterior joints and seams must be sealed. Dissimilar metals must be separated by a non-conductive barrier. Non -Conductive Barriers may consist of one of the following: Black elastic compound tape • Mylar tape • Double -sided structural adhesive tape Where tape barriers are not feasible an appropriate sealant shall be used to provide a protective barrier and a water tight seal. This sealer must be used on all panels and assemblies that are susceptible to water leaks. MOTOR COACH INDUSTRIES neuxE nuMRw.TM �_.----� CME-MiOYEA N. 301J PR�IIBIE"v CM1iKf 16FiRMWOx Pro oL4 #1 111 D4500CT CWWR fIMSX NUMBER WgNG CpLOYR WNE $5 N5] TM IMWCWtIUej wi � ucwtbwomm Reliability Driven" ATTACHMENT B PLEASE SEE ATTACHMENT A AND ATTACHMENT C FOR DETAILS ON MATERIALS AND CORRISION Reliability Driven' ATTACHMENT C CORROSION PROTECTION STANDARD CORROSION PROTECTION MOTOR COACH INDUSTRIES MODEL 102D3 & 102DL3 COACHES 1. INTRODUCTION 2. STRUCTURE 3, EXTERIOR PANELS 4. PREVENTION OF ELECTROLYTIC ACTION gLzyirsm &rd C« imea 1 INTRODUCTION This corrosion standard is designed to enhance the customer's knowledge of Motor Coach Industries commitment to corrosion prevention. The information provided shows designated areas of our coach in which corrosion resistant materials and practices are used. Motor Coach Industries extensive use of stainless steel materials in the design and construction of the Model 102D3 and 102DL3 coaches is a result of over thirty-five years experience in the design and construction of intercity/commuter coaches beginning with the MC -5. This extensive use of stainless steel provides the strength and durability necessary for commuter coaches operating throughout all areas of Canada and the USA. Motor Coach Industries has several customers with coaches operating in the high corrosion areas of Eastern United States which operate MC -9 model coaches that are in excess of 15 years old. The 102133 and 102DL3 models use stainless steel more extensively that the MC -9 models we built 15 years ago. Specifically we have increased the use of stainless steel in the rear upper structure, the front upper structure, the front tire compartment and the engine rails. We believe that the 102D3 and 102DL3 model coaches will have a longer corrosion life than the MC -9 models, many of which are still in operation. STRUCTURE Motor Coach Industries utilizes an abundance of stainless steel as depicted on the attached illustrations. The shaded areas are HSLA steel. The non -shaded areas are type 304 stainless steel. All frame members below the passenger floor that are subject to road splash and are less than .100 inch thick are stainless steel for maximum corrosion protection. All other frame members exposed to splash are HSLA steel and are .100 thick minimum. They are also coated with Tectyl 127CG on all surfaces exposed to road splash. Plywood floor supports in the passenger and drivers area, the sidewall structures and roof structures are not exposed to road spray; and have a lower corrosion resistance requirement. These components are HSLA and are primed prior to incorporation into the coach assembly. The floor supports and sidewall components also are painted with a gray finish coat. Please see attached, stainless steel areas are the *hon shaded items. V.rir sWJUdC« imd« EXTERIOR PANELS & DOORS Motor Coach Industries uses 304 series stainless steel for all exterior panelling below the passenger floor line. Outer sidewall panels above the passenger floor and below the windows are steel, galvanized inside and preprimed outside. The roof panels are preprimed aluminum both side. The front and rear caps are fiberglass. Stainless steel- panels and door frames are also used on'all service doors and passenger doors except the baggage doors. Baggage compartment door frames are aluminum extrusions, top coated before application of the painted aluminum panel or optional fluted stainless steel skin. Non-structural underbody panels used for baggage bay floors and to retain insulation in other areas, are Tectyl coated aluminum or stainless steel. In the wheelwell areas, non-structural closeout panels are stainless steel. Before assembling, all metal body parts are given a thorough anti corrosion treatment. Joints between dissimilar metals are properly insulated with an inert plastic tape to avoid corrosion due to eletrolytic action. All nuts, bolts, clips, washers, clamps, and like parts are zinc or cadmium plated, phosphate coated, black oxide coated, stainless steel, or nylon to prevent corrosion. All exteriorjoints and seams are sealed. PREVENTION OF ELECTROLYTIC ACTION It is a policy at Motor Coach Industries, that dissimilar metals must be separated by a non- conductive barrier. Barriers may consist of one of the following: 1) a black elastic compound tape 2) a mylar tape 3) a double sided structural adhesive tape Where tape barriers are not feasible an appropriate sealant is used to provide a protective barrier and a water tight seal. This sealer is used on baggage floors and all panels and assemblies that are susceptible to water leaks. e„yir swkfm d c� a+d« Y. Be FRONT DRAIN riOLES Reliability Driverf ATTACHMENT D EXTERIOR AND INTERIOR ACESS DOORS Reliability Driven SERVICE COMPARTMENTS AND ACCESS DOORS INTERIOR Access for maintenance and replacement of equipment shall be provided by panels and doors that appear to be an integral part of the interior. Removal of fixtures or equipment unrelated to the repair task to gain access shall be minimized. Access doors, if hinged, shall be hinged with props, as necessary, to hold the doors up and out of the mechanic's way with the exception of the destination sign box door which hinges down and is held by straps in the open position. Panel fasteners shall be standardized so that only two tools are required to service all special fasteners within the coach. These fasteners shall be captive in the panel except for the engine compartment and antenna access hatches. Access doors for the door actuator compartments shall be secured with hand screws or latches, and shall be sealed to prevent entry of mechanism lubricant into the coach interior. All hinges and props must be designed to preclude accidental closure when the panels are opened. PARCEL RACKS A minimum 10 module parcel rack without dividers and compartment doors shall be furnished over all two -passenger seating positions except in the wheelchair door area. Retention cords shall run the length of the rack housing except where air conditioning components are housed. compartments. The parcel rack edge, running along the full length of the aisle, shall incorporate a handhold for use by standees. Passenger headroom measured from the rack end to the top of the seat headrest, shall be a minimum 17 Inches (432 mm). Interior window post caps shall be ABS, thermo formed plastic, off-white in color to provide a clean finished appearance. The interior of the rack shall be vinyl covered aluminum to complement the interior. Parcel racks shall be supported by polycarbonate glass filled hangers spaced approximately 40 inches (1,016 mm) apart. Total capacity shall be a minimum 109 ft 3 (3 m') to allow for ample storage space for carry -on items. Passenger service modules mounted on the underside of the parcel rack shall include individually controlled and adjustable LED passenger reading lights, and an exit signal push button, red in color and individual air distribution outlets receiving air from the parcel rack HVAC system. These outlets shall be adjustable from fully closed to full open position. A minimum of fifteen speakers shall also be provided along the window side of the parcel rack for the driver controlled public address system. Speakers shall broadcast, in a clear tone, announcements that are clearly perceived from all seat positions at approximately the same volume level. Passengers utilizing the securement systems shall be provided identical amenities as provided for all other passengers except that the parcel rack shall be deleted in the arca of the wheelchair lift door. Separate and independent notification will be provided on the dashboard indicator panel for stop request notification from securement positions. EXTERIOR Vertically hinged doors shall be used for the engine compartment and for all auxiliary equipment compartments including doors for checking the quantity and adding to the engine coolant, engine lubricant, transmission fluid and the windshield washer reservoir. The upper engine radiator/C.A.C. compartment door shall be vertically hinged with a locking latch located behind the engine compartment doors. Access to these compartments shall be from outside the coach. Access openings shall be sized for easy performance of tasks within the compartment including tool operating space. Access doors shall be of rugged construction and shall be capable of withstanding severe abuse throughout the life of the coach. They shall close flush with the body surface. All service/maintenance doors, excluding baggage compartment doors, shall be hinged at the top or on the forward edge and shall be prevented from coming loose or opening during transit service or in coach washing operations. Doors with top hinges shall have props stored behind the door or on the door frame. All access doors (except vertically hinged access doors) shall be sufficiently retained in the open position by props or counterbalancing, as with baggage compartment doors. Springs and hinges shall be corrosion -resistant and shall last throughout the service life of the coach. Latch handles shall be sized to provide an adequate grip for opening. Large access doors shall hinge up and out of the way or fold flat against the coach body and shall be easily operable by one person. These doors, when opened, shall not restrict access for servicing other components or systems. Retention devices utilized to hold the engine compartment access doors in the open position shall be heavy duty and designed to last the service life of the coach. UNDERFLOOR BAGGAGE COMPARTMENTS Full width under floor baggage compartments shall be provided between the front and rear axles. Each compartment shall be separated by an aluminum panel except the front and rear bulkheads shall be stainless steeL The compartment doors shall be a two part with the joint at or below the rubrail, fully sealed vertical lift pantograph type. Each door shall include an aluminum or composite frame with an aluminum outer panel. Doors shall be spring counter balanced for ease of operation. The no. 1 right hand, curbside baggage door shall have a key lock. All other baggage doors shall be equipped with air locks. Each baggage door shall have a 4.0 x 10 inch (102 x 254 mm) flush mounted breakaway type latch handle located with a center point approximately 38 inches (965 mm) off the ground. Each under floor compartment shall be pressurized and illuminated with two LED lamps when the doors are opened. The lamp fixtures shall be sealed to preclude the intrusion of dust and moisture into the fixture. The floor of the baggage compartments shall be composite material. PASSENGER ENTRANCE DOOR An electrically controlled, air -operated, power bi-fold door with keyed lock, will be located forward of the right front wheel. The non -symmetrical door will have a clear opening width of 30 inches (762 mm) up to a height of 44 inches (1117 mm). The clear door opening height will be 84.5 inches (2,146.3 mm). The door shall be of composite material construction with a stainless steel kick panel for the lower portion. A molded fiberglass -reinforced panel shall be on the interior of the door. Upper and lower hinge assemblies shall be cast, with a stainless steel lower hinge pin pivoting inside a spherical bearing An upper — primary and lower — secondary window shall be installed in the entrance door. The primary double -glazed window in the upper half of the door shall be of AS -2 laminated heat - absorbing safety glass. The secondary window, located in the lower section of the door, shall be of 0.5 -inch (12.7 mm) acrylic. Door control shall be provided by a momentary switch, located to the left of the steering wheel. An exterior remote external control switch shall also be located in a side-wall pocket by the entrance door,. The door shall have positive automatic air lock with overrule. The air lock will be automatically actuated by a micro switch when the door is in the closed position. An entrance door key lock shall be provided on each coach along with two spare keys. Operation of, and power to, the passenger door shall be completely controlled by a switch located in close proximity to the driver to the left of the steering wheel. A control or valve in the driver's compartment shall shut off the power to, and/or dump the air from the front door mechanism to permit manual operation of the front door with the coach shut down. A toggle switch on the exterior of the coach shall permit opening of the front door. The switch shall be concealed behind an unmarked flip up cover. The door switch cover shall be spring loaded so as to be held in the closed position and be located rearward of the entrance door. ACTUATORS The nominal door opening and closing speed shall be in the 3-5 second range. The maximum door opening and closing speeds will be regulated using fixed, maintenance free orifices and airline sizes. If required, door speeds can be decreased with the addition of a flow -restricting device. Actuators and the complete door mechanism shall be concealed from passengers, but shall be easily accessible for servicing. MANUAL OPERATION In the event of an emergency, it shall be possible to open the door manually from inside the coach after actuating an unlocking device. The nameplate for the entrance door air dump valve shall say: "Emergency Only — To manually open entrance door push knob." All references shall detail the "manual" operation of the door. 14 -SERVICE AND MAINTENANCE .ervice & Access Doors . The exterior view on the foliewirg page identifies at service compartments and exterior access door; for the 04500 series coag f Figure 74 i. Some components may be located and Their locations, components contained within. and accessed through other compartment methods of opening are as fohovs: service doors. li 1 13 4 2 1e 16 — 7 10 12 11 17 NMI ON I IN .i' fit✓ t\ FIGURE 74 — 04500 Exterior Components D4505 Exterior Components ( Figure 74 y 1. Entrarce Door ( Sedan ) 2. Entrarce Door Exterior Synch 3. Fuel Compartment Door 4. Battery Compartrnert 5. DEF Compartment Door 6. Rear Side Service Compartmert Door 7. AC Cordenser 8. Electr cal Parel Front Jurc6or Box 9. Radiator Compartment 10. Air Cleaner Service Door 11 . A C Compressor Senrce Door 12. Engire & Coolirg Compartmert DDor LatC e`; 13. ID Maker light—High Mourted 14. Brake Light—High Mourned 10. Rear Tai Light Cluster 16, Back—up Lghts 17. Bumper and Spare Tire Compartment 18. Dirediional Light Date September 2013 SII D Series Maintenance Manual Page 3D4-1 Driven' SECTION 3D4 BAGGAGE & SERVICE COMPARTMENT DOORS, EMERGENCY ESCAPE HATCHES CONTENTS OF THIS SECTION SUBJECT PAGE BAGGAGE AND SERVICE COMPARTMENT DOORS ....................... 3D4-3 General Description...............................................3D4-3 MAINTENANCE.....................................................3D4-7 Inspection.......................................................3D4-7 Adjustment......................................................3134-7 Removal........................................................3D4-8 Installation...................................................... 3134-9 EMERGENCY ESCAPE HATCHES ...................................... 3134-10 General Description ...............................................3134-10 MAINTENANCE.....................................................3D4-10 Inspection.......................................................3D4-10 Adjustment......................................................3D4-10 Removal........................................................3134 -10 Installation...................................................... 3D4-11 SPECIFICATIONS................................................... 3D4-13 SERVICE TOOLS .................................................... 3134-13 Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 3D4-2 D Series Maintenance Manual Reliability Driven THIS PAGE INTENTIONALLY LEFT BLANK Copyright 2013 — Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved, PM 03-26-0219 W D Series Maintenance Manual Driven BAGGAGE AND SERVICE COMPARTMENT DOORS General Description The coach is constructed with three baggage bays, numerous service compartments, and two roof escape hatches. All baggage bay doors, service compartment doors, and emergency exri ways are hinged. Date September 2013 Page 3D4-3 All baggage bay doors, lower service compartment doors as well as the sedan style entrance door and wheelchair lift cassette door on the RH side are fitted with black rubber rub rails. The condenser compart- ment door on the LH side has a formed metal rub -rail section. Keyed -alike locks are used on baggage and service doors. The baggage and service compartment compo- nents locations are shown in LH (Roadside) View and RH (Curbside) View. All compartments and doors are in the same locations, but may be cosmetically differ- ent. Figure 1. LH (Roadside) View Item IDescription 1 Front J- ox 2 Front Side Service Door 3 Baggage Bay #1 4 Baggage Bay #2 5 Condenser Compartment 6 Baggage Bay #3 7 Rear Side Service Door Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 3D4.4 D Series Maintenance Manual Reliability Driven 45019 Figure 2. RH (Curbside) View nem Description 8 Rear Side Service Door 9 Baggage Bay #3 10 Battery Compartment 11 Fuel Tank Filler Door 12 Wheelchair Lift Cassette Door (with LED lights) 13 Baggage Bay #2 14 Baggage Bay #1 15 'Sedan Style Entrance Door (Bi -Part Style Entrance Door Not Shown) 16 "WCL Sliding Door 17 DEF (Diesel Exhaust Fluid) Filter Door 'Refer to section 3131 of this manual for Sedan Style Entrance Door maintenance (Section 332 lot Bi -Part Style Entrance Door maintenance). "Refer to section 31D3 of this manual for WCL Sliding Door maintenance. Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 W D Series Maintenance Manual Page 3D4-5 Driven 11285 Figure 3. Rear View Item Description 1 Radiator Compartment 2 A/C Compressor Service Door 3 Engine Service Doors 4 LH Access Door The engine cooling compartment (radiator) doors are located above the rear engine access doors. To open the engine cooling compartment doors, open the curbside rear engine access door and pull the lever down, disengaging the lever from the curbside engine cooling compartment door. Locate the door latch and pull outward. Pull doors outwards until the doors are fully open and secured. NOTICE Ensure that the lever Is always engaged when the engine cooling compartment doors are closed to prevent inadvertent opening due to high internal compartment pressures. Components Front Junction Box Door The electrical junction box (J -box) service door is located below the driver's window, see LH (Roadside) View. The door is fitted with a piano type front hinge and held closed by two quarter -turn Dzus fasteners. A prop rod holds the door open. This door provides ac- cess to the audio amplifiers, entrance door overrule knob, various circuit breakers and relays, warning buzzer, speed switch, electrical modules, and power converter 110 VAC receptacle. Front Side Service Door A left front side service door, see LH (Roadside) View, located below the J -box service door, is front - hinged and held closed by two quarter -turn Dzus fas- teners. This door provides access to the front -bumper release handle, accessory air reservoir, emergency fill valves, steering components, windshield washer, and horns. Condenser Compartment Door The condenser compartment door is located to the rear of the #2 LH baggage door, see LH (Roadside) View. The door is fitted with a piano -type front hinge, and is held closed by fasteners. A prop rod is provided to hold the door when fully opened. This door provides access to the condenser fan and motor, receiver tank, inspection panels, and other air conditioning compo- nents. Battery Compartment Door The battery compartment door see, RH (Curbside) View is top -hinged and held closed by a flush -mounted paddle handle latch. A prop rod is provided to hold the door open while providing access to batteries, air con- ditioning filter, and battery disconnect switch. This door is fitted with a small hinged door for quick access to the disconnect switch. NOTICE When the battery compartment door is fully opened, It will interfere with operation of the WCL Sliding Door. To prevent interference when opening the sliding door, either close the battery compartment door or prop it open to the first position only. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-28-0219 Date September 2013 Page 3D4-6 D Series Maintenance Manual RelioNlity en Rear Side Service Doors The engine compartment is accessible through LH and RH rear side service doors, see LH (Roadside) View and RH (Curbside) View. The doors are front - hinged and held closed by a flush -mounted paddle - handle latch. A prop rod is provided to hold the doors in the open position. Engine Service Doors The rear, engine -compartment service doors are side hinged. A flush -mounted, paddle -handle latch is installed on the right door which overlaps the edge of the left door. Prop rods are provided on both doors to hold them in the open position. Radiator Compartment Door The radiator compartment doors are side -hinged and held closed by two spring-loaded latches. Gas - charged springs hold the door when fully opened. Ac- cess is provided to the radiator, charge air cooler, surge tank, fan belts, and fan controls. Fuel -Tank Filler Door 11286 Figure 4. Fuel Tank Filler Door The fuel -tank fill access door is a side -hinged spring -assisted panel. The main, fuel -door panel, is re- tained at the top by two bolts and at the bottom by pins. This allows access to the fuel tank assembly and drain plug removal if necessary when servicing the coach. DEF (Diesel Exhaust Fluid) Filler Door The DEF fill access door is a side -hinged spring - assisted panel with a keylock located to the rear of the curbside baggage bay #3. LH Rear Access Door The door is side -hinged and held closed by two quarter -turn Dzus fasteners. A/C Compressor Service Door The air conditioner compressor is accessible through the service door mounting near the RH backup light. The door is side -hinged and held closed by two quarter -turn Dzus fasteners. Baggage Compartment Doors 11287 Figure 5. Baggage Compartment Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PSN 03-26-0219 Date September 2013 0 D Series Maintenance Manual Page 3D4-7 1mven Wheelchair -Lift (WCL) Cassette Door Figure 6. Baggage Door Hinge and Cable Baggage compartment doors have a clear 33 x 54 in. (840 x 1380 mm) opening provided to each compartment on both sides of the coach (see LH (Roadside) View and RH (Curbside) View). All com- partment doors (except #2 RH) are fully sealed, vertical lift type, and each has a flush -mounted, breakaway type, safety, hold -open catch with provision for padlock and customs seals (see Baggage Door Hinge and Cable). The #2 RH (curbside) baggage door is side - hinged. Doors are counterbalanced with springs for ease of operation. To open, insert fingers under latch, then pull outward and up. To close, hold latch in open position, pull downward on door and push down on latch to secure door. Rubber bumpers prevent the door from contacting the body when opened. The wheelchair -lift (WCL) cassette door is located in the lower portion of the #2 RH (curbside) baggage door. It has keyed access, incorporating a safety inter- lock switch and a power switch. The door is bottom - hinged and held closed by two top spring -bolt latches operated by a flush -mounted paddle handle. Spare Tire Compartment The spare tire compartment is accessed by lower- ing the front bumper. The bumper release handle is ac- cessed from the front -side service door. Thd bumper is bottom hinged and is provided with an over -center an- gle latch to hold the bumper in the down position. The bumper is counter -balanced (to assist in opening and closing) and is retained by two spring bolt latches. MAINTENANCE Inspection 1. Inspect the pulley cables for fraying. Replace the cables if necessary. 2. Check the pulleys for wear and cracks. Re- place them if either of these conditions ex- ists. Adjustment !NOTICE When adjusting baggage doors for proper locking and/or sealing, always check that the handle and locking -rod mechanism is adjusted for maximum contact with locking lugs and/or catches. Copyright 2013 -Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 3D4-8 D Series Maintenance Manual Reltabiltly Drtverr Removal Baggage Door (Except #2 RH Swing Out Door) Baggage door removal should be performed by 2 two persons. 1. Set park brake and turn battery disconnect switch to OFF position. 3 2. Fully open baggage door and support it to prevent falling when cables are removed. O O O 11289 Figure 7. Rear View Mem Description 1 Cotter Pin 2 Door Handle 3 Pivot Pin 4 Jamnut 5 Yoke 1. Remove cotter pin (on inside of door handle) retaining the yoke pivot pin. 2. Slide out yoke pivot pin. Loosen jamnut and turn threaded yoke to desired length. 3. Tighten jamnut and reassemble in reverse order. NOTICE If baggage door locks too tightly and pinches seal at either top or bottom, or locks too loosely, adjust the upper or lower catches on the inside edges of the baggage compartment. 4. Loosen retaining capscrews and slide upper or lower catches to desired position and re - tighten. Figure B. Rear View Item Description 1 Pulley 2 Spring 3 Spring Retainer 4 Lower Catch 5 Upper Catch 6 CabStable Assembly 7 ilizer Tube 8 Clovis Pin 3. Using baggage -door -cable pulling tool (20-46), pull the cable back to allow removal of the clevis pins that attach the pulley ca- bles to the stabilizer tube. 1 The baggage door opening mechanism cable assembly is under tension. Exercise extreme caution during removal and installation. 4. Remove the stabilizer tube from mounting brackets. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. Pini 03-26-0219 Date September 2013 Reliability n D Series Maintenance Manual Page 3D4-9 ! NOTICE Baggage door must be supported at this stage to To remove the battery -door, small, disconnect prevent it from falling during final removal switch door, the inner plastic panel must be procedures. removed to access fasteners. 5. Remove the screws that secure the hinge panel to the coach body and remove door, stabilizer tube, and hinge panel as an as- sembly. To remove the rest of the cable and spring assem- bly, follow these additional steps. 6. Remove the cable end/spring plug from the spring by rotating the plug. 7. Remove the four capscrews that mount the spring retainer to the upper -compartment ceiling channel. 8. Rotate the spring to remove it from the spring retainer. #2 PH Swing Out Door 1. Set park brake and turn battery disconnect switch to OFF position. 2. Open door and remove screws from hinge and remove door. Fuel Door 1. Set park brake and turn battery disconnect switch to OFF position. 2. Fully open the small filler door to gain ac- cess to the main door/panel capscrews. 3. Remove capscrews from the top mounting brackets and lift the door (with lower retain- ing pins) out of the frame holes. Hinged Service Doors 1. Set park brake and turn battery disconnect switch to OFF position. 2. Fully open door and support it to prevent falling when hinges are removed. 3. Remove all prop rods or spring clip assem- blies from door. 4. Remove all hinge fasteners and remove door from coach. Installation Baggage Door 1. Reassemble springs and cables, following the above steps in reverse order. 2. Position and support the baggage door in the fully open position and install door in re- verse order of the Removal procedure. #2 RH Swing Out Door Position door and secure hinge with screws. Fuel Door Position door/panel lower retaining pins into frame holes and tighten capscrews. Hinged Service Doors Position and support the door in the fully open po- sition, and reinstall prop rod, spring clips, and hinge fasteners. Lubrication Lock Cylinders Apply dry graphite compound, powdered graphite, or graphite oil to lock cylinders. Do not use spray grease on the lock cylinders. Refer to Section 10 for lu- brication intervals. NOTICE To prevent gumming and sticking, never apply spray grease to the lock cylinders. Latches 1. Open the door as wide as possible. 2. Apply spray grease to the inside of the latch mechanism. 3. Assure that the lubricant is worked into the latch by opening and closing the door sever- al times. Clean any excess lubricant from the door with a clean shop rag. Refer to Section 10 for lubrication intervals. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 3D4-10 D Series Maintenance Manual EMERGENCY ESCAPE HATCHES Adjustment General Description Two 22.75 x 22.75 in. (578 x 578 mm) escape hatches are located in the roof. The hatches are used for emergency evacuation of the coach. Turn knob from LATCHED to TO EXIT position and push to open hatch. MAINTENANCE Inspection Examine the surface of the rubber seal surround- ing the hatch opening. An impression should be visible in the seal where the hatch has made contact. If the im- pression is a continuous unbroken line, the seal is good and requires no adjustment. Inspect the handle and locking rod mechanism for maximum contact with locking lugs and/or catches. 1. Open the hatch cover. 2. Apply chalk to the lip of the hatch opening. 3. Close and reopen hatch. Inspect seal to de- termine hatch position (chalk marks indicate hatch position). 4. Adjust the catches up, down, front, or back as required to position the hatch cover. 5. Re -apply chalk to lip of hatch opening; clean the seal surface. Close and reopen hatch. Inspect the seal to determine hatch position; readjust as necessary. NOTICE It additional forward or rearward adjustment is required, remove the catches and elongate the slotted holes. Removal Set park brake and turn battery disconnect switch to OFF position. Unfasten hinge mountings and remove ac- cess cover. Remove seal material from mount ring trough and drill out mounting rivets to re- move mounting ring. Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 MC1 Installation D Series Maintenance Manual Date September 2013 Cage 3D4-11 3_< >_ 2 Figure 9. Transpec Roof Hatch 45937 (tem Description 1 Transpec Root Hatch 2 Tapping Screws 3 Trim Molding 4 White Sikaflex 1. Clean mating surface of exterior roof skin with isopropyl alcohol. Allow 10 minutes to flash off. 2. Align hatches with hinged side to front and centered in the frame opening. Arrow fea- ture on the roof hatch to be pointing to the front of the coach. 3. Clean the roof adjacent to the hatch using sika cleaner and a lint free cloth. Allow 5 to 10 minutes to flash off. 4. Apply Sika primer within one hour of the cleaner, using a brush or roller. Allow 10 minutes to flash off. 5. Apply white Sikaflex to the perimeter of the hatch within one hour of the primer. 6. Clamp roof hatch for 20 seconds using 10 Ibf (44.5 N). 7. Clean away excess butyl squeezed out from hatch clamping. B. Install interior trim molding flush with ceiling panels at specified locations. 9. Attach hatch lid with hardware provided. Torque bolts to 45-55 in -Ib (5.1-6.2 Nm). 10. Complete the installation of the roof hatches by repeating the Inspection and Adjustment procedures as necessary. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 3134-12 D Series Maintenance Manual aellabillty Driven r t)FM err J 16 43484 Figure 10. Transpec Roof Hatch Breakdown Item Description 1 Link and Plunger Assembly 2 Gasket Kit -Standard 3 Inner Release Handle 4 Release Handle Assembly 5 Release Handle Shield Assembly 6 Frame 7 DPSV 111 Cover H Vent Adhesive/Sealant 9 Shoulder Boft-Torque to 75 in -Ib (8.47 Nm) Max. 10 Plunger Vent Coil Spring 11 Hinge Cover 12 Fixed Hinge 13 Release Hinge 14 Handle Base 15 Tont Screw 16 Flat Head Screw 17 Hinge Pin 18 Decal 19 Decal 20 Decal Opening a Transpec Hatch 1. Rotate the red knob 90 degrees in either direction. 2. Push the red knob into the lid. 3. Continue to push the lid to the fully open po- sition. Closing a Transpec Hatch 1. If the hatch was opened with the lid in the fully closed position, the release hinge will still be in the down position. 2. Push the release hinge upward. 3. Lower the lid into position. 4. Guide the release hinge into the handle base on the lid. 5. Pull down on the top of the lid to force the release hinge and the lid together until you hear it click into place. This will be the spring loaded handle setting in place. 6. Grasp both sides of the lid and pull down to fully close the hatch. 7. Rotate the red knob back into the LATCHED position. 8. The red knob should be in the LATCHED position during normal operation of the vehi- cle. A CAUTION Ensure the escape hatches are fully closed and latched before operating the coach. Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PM 03-26-0219 Date September 2013 D Series Maintenance Manual Page 3134-13 Reliability Drlveri SPECIFICATIONS BAGGAGE DOOR ASSEMBLY Manufacturer..............................................................................................................................................................mut PADDLE LATCHING HANDLE Manufacturer............................................................................................................................................................... MCI ROOF HATCH Manufacturer......................................................................................................................................................Transpec SERVICE TOOLS SOME OF THE TOOLS USED FOR MAINTENANCE PROCEDURES OUTLINED IN THIS SECTION ARE NONSTANDARD. THEY ARE, HOWEVER, AVAILABLE FOR PURCHASE THROUGH MCI SERVICE PARTS. WHERE PRACTICAL, THEY MAY BE FABRICATED AT THE SERVICE FACILITY. Baggage Door Cable Puller Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Reliability Driven' ATTACHMENT E DIMENSIONAL DRAWINGS [Type text] The following notes are applicable where indicated. All dimensions provided are nominal. I. Includes front bumper and rear bumper rub rail 11. Excludes fenders, splash guards, mirrors and side turn lights Ill. Dimensions are based on coach in a normal operating position using 315180R x 22.5 tubeless tires IV. Departure angle takes into account installed rear skid V. Dimension is based on a door to door frame measurement, below the upper door hinge cover VI. Vehicle weight could vary from coach to coach, depending on equipment specified LENGTH win m Over body 44'9" 13.64 Over bumpers, basic' 45' 5" 13.84 Over optional rear help bumper 45'6" 13.87 WIDTH in mm Overall - body 102 2,590.80 HEIGHT 01 in mm Overall: over roof hatches 137.00 3,479.80 over roof 135.00 3,429.00 WHEEL -BASE in mm Center front axle to center drive axle 318.00 8,077.20 Center drive axle to center trailing axle 48.00 1,219.20 OVERHANG in mm Front body 74.50 1,892.30 Over front bumper 75.90 1,927.86 Rear body 149.41 3,795.01 Over rear bumper with rubber cushion pad 153.13 3,889.50 Over optional rear help bumper 154.13 3,914.90 [Type text] TRACK Front Driving (center of duals) Trailing TURNING RADIUS °1 (With locked Tag axle) Front tire: right-hand turn left-hand turn Front bumper: right-hand turn left-hand turn Steering wheel turns, lock -to -lock Turning angle: right-hand or left-hand in mm 85.60 2,174.24 76.50 1,943.10 85.60 2,174.24 Win m 45' 8" 13.93 45'8' 13.93 50' 8" 15.4 50,101, 15.5 6 360 - Outer, 420 - Inner BUMPER CLEARANCE III in mm Ground to center line: front (apex) 22.25 565.15 rear 24.00 609.60 GROUND CLEARANCE ° in mm Ground to body at center 10.00 254.00 Approach angle IV 9.50 6.20 Departure angle Breakover angle ENTRANCE STEP HEIGHT ° in mm Ground to first step: coach in normal operating 15.50 393.70 position coach in kneeled position 12.50 317.50 FLOOR HEIGHT FROM GROUND (at axle) .° in mm Front (first row of seats only) 51.00 1,295.40 Rear 54.00 1,371.60 HEADROOM in mm Aisle to ceiling: front (at front of first seat) 87.25 2,216.15 rear 78.25 1,987.55 Floor to parcel front (at front of first seat) 63.62 1,615.95 rack: front(at rear of first seat) 60.56 1,538.22 rear 60.56 1,538.22 (Type text] PASSENGER, SIDE WINDOW ELEVATION in mm Floor surface to glass Top (front of first seat) 63.80 1,620.52 line: 10,300 4,672 Bottom (front of first seat) 31.62 803.15 Top (remainder of coach) 60.80 1,544.32 Bottom (remainder of coach) 28.62 726.95 ENTRANCE DOOR in mm Clear opening width (at door frame) 27.00 685.80 Height of clear opening 84.63 2,149.60 EMERGENCY ESCAPE ROOF HATCHES in mm Length of opening, each 22.75 578.60 Width of opening, each 22.75 578.60 Total Clear Opening Area 518.00 in` 3,342.00 cm` center of front hatch to front bumper 89.50 2,273.30 center of rear hatch to center of front hatch 289.87 7,362.70 AISLE Center aisle ramps Width, between seats in mm 14.5 x96.0x9.0 368 x 2,438 x 229 14.00 355.60 VEHICLE WEIGHT V1 Ibs kg Net basic 37,700 17,100 Payload capacity 10,300 4,672 Gross vehicle weight 48,000 21,772 Gross vehicle weight —After January, 2009 50,000 22,678 [Type text] 3 - CAPACITIES NOTES: The following notes are applicable where indicated, all dimensions provided are nominal: VII. Volume provided excludes the provision of the following: • Kneeling system control module • ATEC, DDEC junction box • 110 -volt inverter (option) • Wheelchair lift control module (option) • ABS control box (option) VII. Volumes exclude provision of parcel rack mounted air conditioning, wheelchair lift, and audio/video options. Total volume and curbside parcel rack volume are reduced nominally 5.80 ft3 (0.16 m) when the optional wheelchair lift is installed BAGGAGE COMPARTMENT VOLUME (underfloor) V" W m' Front 127.00 3.59 Center 116.00 3.28 Rear 157.00 4.44 Total Volume 400.00 11.31 PARCEL RACK COMPARTMENT VOLUME Vill W m' Road -side 57.62 1.63 Curb -side: with lavatory (basic) 51.38 1.45 without lavatory (optional) 57.62 1.63 Total Volume with Lavatory "' 109.00 3.08 LAVATORY TANK CAPACITY US gal L Lavatory Chemical Tank 18.5 70.0 WINDSHIELD WASHER US gal L Windshield Washer Fluid Reservoir 3.9 15.0 [Type text] [Type text] 192.0 727.0 AIR COMPRESSOR RESERVOIR CAPACITY in' cm' Wet Tank 2,059 33,747 Front Brake Service Dry Tank 2,059 33,747 Rear Brake Service Dry Tank 2,059 33,747 Parking Brake Release Tank 2,059 33,747 Accessory Air Tank 1,180 19,340 ENGINE US gal L Engine Cooling System (with surge tank and coolant recovery) 29.5 111.7 Engine Lubricating Oil — Total Capacity S-60— 9.5 36.0 R134a C-13 —10.6 40.0 ISM —10.3 39.0 FUEL TANK CAPACITIES US gal L Aluminum Tank Main Tank Fuel Capacity — Total Volume 192.0 727.0 Useable Volume — 95% of total volume 182.0 689.0 Polyethylene Tank (after January 5, 2009) Main Tank Fuel Capacity — Total Volume 173.0 655.0 Useable Volume — 95% of total volume 164.0 621.0 TRANSMISSION OIL CAPACITY US gal L ZF-ASTronic Model 12 AS 2301 3.2 12.0 ALLISON B500 Gen IV — No Retarder (reference only) Initial fill — factory (excluding external circuits) 10.75 41.0 AIR CONDITIONING REFRIGERANT CAPACITY lbs kg R134a 37.0 16.8 [Type text] 4 - DIAGRAMS Body, Door Clearance & Major Dimensions Diagram 21.00 in. -- - (533 mm) p •�36.00 in. (911 mm) Baggage Bay Door pfV � • ( m, Battery Compartment 6ervice Door 102.00 in. (8.5 (1.) (2.59.) REAR VIEW J 13° L } 34.54 in. IBR mm) ; Front Roof Hatch _ 102.00 in. (8.5 X.) (2591 mm) FRONT VIEW I Rear Roof Hatch 38.50 in. (978 mm) Height From .. ROof"ne co 6ronne 71 29 ft (3.44 m) 38 N 10 in. 111.8 m) ., �- - --�-y S I- - y ROADSIDE VIEW 31.25 in. f 26.5 R. (8.1 m) 48.88 in. (794 m.) (1219 m.) 6.2 8.- (7.89 m) 45.3 K 113.8 m) 24.15 R. 7.50 k. Biabnce Benreen Nxch Gnrers y (7.36-) ��� (22B m) few Free - Top of RodiHah 11.42 k (3.48 m) 6.Y 18.88 in. 284 mm t 12.58. CURBSIDE VIEW } (3.88 m) 12.8 ff. (3.89 m) NOTE. All vertical dimensions are at normal ride height. Optional Wheelchair Lift is shown for reference. 6.2 k. (1 89 my Rt in. (341.m) } 27.00 in. (686 mm) [Type text) Turning Radius and Door Clearance Diagram (1885 mm) FRONT OVERHANG (Over Bumper) 318" (8077 mm) WHEELBASE 45' S" (13.85 m) Overall 48.0' 1 1219 mm 153.13" (3889 mm) REAR OVERHANG (Over Bumper) TAG - 85.56 2175 mm TRACK \ Turning Radius Configurations BASIC CONFIGURATION With Locked Tag Axle 50.53 ft. (15.43m) RH Tum 50.64 ft. (15.49 m) LH Turn OPTIONAL CONFIGURATION 7.8Tag Axle 47.888 ft.. (14.59 (14.59 m) RN Tum \ 47.90 ft. (14.60 m) LH Tum 36 42' - 755 I 1917mm INOlf STEERING ANGLES 76.51 194.9 mm -� TRACK — COACH CENTERLINE .DRIVE AXLE REAR DRIVE TAG AXLE CENTER IS in. THEORETICAL ' TURNING CENTER X66, y D4505 - Steering Angle 2175mm & Turning Radius TRACK 162' 2590 mm Ove/a6 Maintenance Manual GENERAL DESCRIPTION The bl-part entrance door has two door leaf panels that move out and away from each other as the door opens, providing a 27 x 831n, (609.6 x 2108 mm) open - Ing. The door is operated pneumatically. Two air cylin- ders move the door leaf panels. The door Is electroni- cally controlled. Vertical shaft assemblies are installed at each side of the door opening. Each shaft is attached to a door leaf panel and to an air cylinder that rotates the shaft. Shaft rotation opens and closes the doors. A toggle switch on the control panel actuates the air cylinders. The shaft bearings and linkages are contained in a bearing box assembly below the stepwell. Components BI -Part Door Leaf Panels The door leaf panels are attached to the rotary shaft assemblies. The door leaf panels have double - glazed tempered -glass windows and Lucite sashes. For safety, the meeting edges of the.leaves Incorporate wide flexible rubber cushions. BI -Part Door Bearing Box The bearing box assembly contains the lower sta- bilizing rod assembly. This rod connects the lever arms of each shaft assembly to help coordinate movement between both door leaf panels. The box provides front and rear cut-outs for actuating shaft bearing mount- ings. Solenoid Valve A four-way, two -position, 24 volt, dual solenoid valve controls the flow of air to the cylinder ports. One valve portion is normally -open, while the other Is nor- mally -closed. The valve is located In the pocket below the RH dash. Date October 2011 Page 3D1-3 BI -Pan Door Shaft Assemblies The vertical shaft assemblies are Installed at each side of the door opening. The shaft rotates in bearing blocks attached to the coach body, and on bearing as- semblies mounted on the bearing box. The control arm assembly is attached to the bottom arm of each shah assembly to assure unison in movement. A stabilizing tube assembly is attached to the top bearing block arm and door leaf panels to retain the glide path. BI -Part Door Air Cylinders Door actuation is provided by two dual acting air cylinders. The air cylinders are attached to each of the actuating shafts by control arms. The front leafs cylin- der is located in the pocket below the RH dash. The rear leaf's cylinder is located in the pocket below the modesty panel. The extend position closes the door and the retract position opens the door. Door Switches The momentary -on type door switches are located on the right-hand switch panel and adjacent the kneel switch In the exterior switch pocket The exterior switch must be in the open position in order for the interior switch to open and close the doors. Operation With the interior door control switch closed, the four-way solenoid valve is energized. The normally - open portion doses supply air to the retract ports of the air cylinders. The normally -closed portion opens supply air to the extend ports of the cylinders. Simultaneously, air is allowed to exhaust from retract ports of the cylin- ders. The extended cylinders push the shaft arms out- ward, and cause the shaft to rotate. The rotating shafts pulls the door arms in, moving the door leaf panels in- ward and toward each other at entrance opening cen- ter. Copyright 2011 — Motor Coach Industries Inl'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-15-9323 Date October 2011 Page 301.4 Maintenance Manual Figure 1. Si -Part door Pneumatic Diagram MAINTENANCE Adjustments NOTICE After performing any of the following adjustments, lubricate all bearing and pivots with Multi -Purpose Grease (lubrication specification S-16 through S-19). Wipe excess grease from all components. After lubrication, manually move shafts and linkage through full travel. Check for smooth movement without any binding. Action should be stiff but not excessively hard to move manually. Shaft Bearing Blocks Check fore and aft dimension between shaft cen- ters. Remove shims between brackets and spacers if roam Description short. Add shim pack to the underside of standard spacer If long. Ensure that both brackets are shimmed 1 4 -Way valve— equally. When the switch is open, the solenoid valve is de - energized. The normally -open portion opens supply air to the retract ports of the air cylinders, and the normal- ly -closed portion closes supply to the extend ports of the air cylinders allowing air to exhaust from the extend ports of the cylinders. The retracted cylinders pull the shaft arms inward, cause the shaft to rotate, pushing the door arms out and move the door leaf panels out- ward and away from each other. Supply air is routed through the manual dump valve. in emergencies, the valve exhausts air from the door operating cylinder, and allows manual opening of the doors. NOTICE Doors should open to a clear opening of approximately 27 In. (609.6 mm). 1. Turn disconnect switch OFF. Actuate the door manual air dump valve. 2. Loosen the bearing block mountings. Install or remove shims as required. 3. Tighten the bearing block mountings. Re- check dimensions. Copyright 2011 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PIN 03.15-9323 Maintenance Manual Shaft Bumper Stops 2 - Figure 2. Shaft Bumper Stops 1. Turn disconnect switch OFF, and actuate the door's manual air dump valve. 2. Unfasten Jamnut and adjust rubber bumper stops on both shafts to 5/8 in. (15.875 mm). 3. Tighten Jamnut to lock bumper In position. Shaft Arm Rod Ends Date October 2011 Page 3D1-5 NOTICE This adjustment is critical in attaining correct door operation. 2 } 7 3' Figure 3. Shaft Arm Rod Ends Item Description 1 Socket Assembly 2 1-1l2 in. Top and Bottom Arm 3 Jam Nut --- . Copyright 2011 - Motor Coach Industries Int'I, Inc. and As subsidiaries. All Rights Reserved. P/N 03-15-9323 Item Description 1 - Rubber Bumper 2 Jam Nut 3 Shaft Arm 1. Turn disconnect switch OFF, and actuate the door's manual air dump valve. 2. Unfasten Jamnut and adjust rubber bumper stops on both shafts to 5/8 in. (15.875 mm). 3. Tighten Jamnut to lock bumper In position. Shaft Arm Rod Ends Date October 2011 Page 3D1-5 NOTICE This adjustment is critical in attaining correct door operation. 2 } 7 3' Figure 3. Shaft Arm Rod Ends Item Description 1 Socket Assembly 2 1-1l2 in. Top and Bottom Arm 3 Jam Nut --- . Copyright 2011 - Motor Coach Industries Int'I, Inc. and As subsidiaries. All Rights Reserved. P/N 03-15-9323 Date October 2011 Page 3D1.6 Maintenance Manual ,�—w 1L s �t Figure 4. Bi -Part Entrance Door Control Mechanism Copyright 2011 —Motor Coach Industries Int'I, Inc, and its subsidiaries. All Rights Reserved. PM 03-15-9323 Description--- 1 Solenoid Valve 2 Air Cylinder 3 shaft 4 Upper Hinge Cover 5 Steering Arm 6 Timing Link 7 Bearing - -- - Shaft Seal Boot ftB8 Bearing Block 10 Front Of Coach Copyright 2011 —Motor Coach Industries Int'I, Inc, and its subsidiaries. All Rights Reserved. PM 03-15-9323 Date October 2011 Maintenance Manual Page 3D1-7 Check rod end stick -out, and adjust for minimum door movement. 1. Turn disconnect switch OFF. Actuate the door's manual air dump valve. 2. Loosen jamnut and adjust rod ends on both shaft arms to 1.1/2 in. (38.1 mm). 3. Tighten jamnut to lock the rod end in posi- tion. Door Leaf Panel Removal NOTICE The removal procedure may require two technicians. 1. Turn battery disconnect switch OFF. 2. Actuate the entrance door switch to open doors, and dump all air via the manual over- ride dump valve. 3. Unfasten and remove the top shaft arm cov- ers. 4. Unfasten the upper front and rear door leaf panel -to -shaft arm mounting bracket cap - screws. S. Unfasten the lower door leaf panel -to -shaft arm mounting bracket capscrews and re- move the doors. Door Control Mechanism Removal 1. Turn battery disconnect switch OFF. 2. Actuate the entrance door switch to open doors. Dump all air via the manual override dump valve. 3. Remove the air cylinder access panels. 4. Remove the bearing box access panel. 5. Remove the front and rear control arm clamp bolts. Remove clamps and control arm assembly from the shafts. 6. Loosen stop collar set -screws. Remove col- lars from bottom of shafts. 7. Remove bottom bearing assemblies from bearing box studs and slide rubber boot off shafts. 8. Remove the top shaft locknut retaining the upper shaft bearing block. 9. Remove the upper stabilizer tube assem- blies from upper shaft bearing block mount- ing arm. Remove the upper bearing block. 10. Remove the lower bearing block from shahs. 11. Rotate shafts to the air cylinder extend post - tions. Loosen cylinder rod ends from shaft arms. 12. Lift shafts with brackets out of bottom bear- ing assemblies and remove for disassembly. 13. Tag and disconnect all air line to the air cyl- inders. 14. Remove the air cylinders from their mount- ings. Door Leaf Panel Installation Reinstall the door controls and door leaf panels in reverse order of Door Leaf Panel Removal. Check door adjustments after installation is complete (see Door Leaf Panel Opera- tional Check). NOTICE install air cylinder rod assemblies with lubrication fittings facing stepwell. NOTICE Check position of upper and lower hanger brackets on each door leaf. Ensure that brackets are positioned correctly. Door Leaf Panel Operational Check 1. Move both door panels manually through full open and closed positions. Check for interference between front door panel and body panels, right-hand exterior rear view mirror, etc. 2. Move door panels to closed position. Check for door to body clearances. 3. Place battery switch in ON position. Place manual air valve at driver's position to air ON position. 4. Check both the interior and exterior opera- tor's door control switch to cycle door from both positions. Copyright 2011 - Motor Coach Industries Int], Inc. and its subsidiaries. All Rights Reserved. PIN 03-15-9323 Date October 2011 Page 3D1-8 Maintenance Manual NOTICE To check door operation, the coach air system should have a minimum of 85 pal (586 kPa). 5. With air on and door closed, ensure the fol- lowing: a. A proper seal exists between both door panels. b. Clearance between doors and body Is 1/41n. (6.35 mm) minimum from top to bottom. At top of doors, clear- ance should be 1/8 in. (3.175 mm). If these clearances are not correct, re- ferto TROUBLESHOOTING. C. Inner feather body seal fits snug to sides and top of doors. d. Door panel contours follow contour of coach body from top to bottom. TROUBLESHOOTING BI -Part Door Condition Correction Door panel too high or too low. Loosen capscrews in upper and lower hanger brackets. Move door panel up or down as required. Tighten capscrew in brackets. Door panel on angle. Loosen capscrews in top or bottom bracket. Move door panel in direction required to correct clearance between door and body. Daor control arms binding. (Center of control arms Release air with the air dump valve. Disconnect should move up and down slightly with doors fully one rod end from the end of the tight arm, close dosed.) doors manually, and reapply air. With doors dosed, adjust rod end until it can be easily reinstalled. Replace and tighten nut. Insufficient travel of shaft and arm. Loosen jamnuts on master cylinder linkage rod. Turn rod required number of turns to Increase length of rod. Tighten jamnuts. Too much travel of shah and arm. Loosen jamnuts on master cylinder linkage rod. Turn rod required number of turns to decrease length of rod. Tighten jamnuts. Insufficient tension at the top of the door. Loosen the locknut at the outer end or the lower arm and screw bolt out until pressure is equalized from top to bottom. Retighten the locknut. Insufficient tension at the bottom of the door. Loosen the locknut at the outer end of the lower arm and screw boa in until pressure is equalized from top to bottom. Retighten the lockout. Copyright 2011 —Motor Coach Industries Intl, Inc. and Its subsidiaries. All Rights Reserved. PIN 03-15-9323 INITIAL Ma H L Y ba _ COACH COORDINATES I d t! i•w • 4 i t Y�T•.yill;�i1 .� u vrew.a _ ..•.._ r.uw�_. - ®�wu]�MIY �.i.l•.wI�P. eVLAW..•.(Y �sW ]..tt ILII Ili ©~MWl .Mw.x auWs nRaw..Rx �nsW� � I, oho:,. i At -1. ..K�tl LT.' I .W�M•��L .x,A.. -L. ©q.xWt,.,• I p x�owr000e�wa ww.c..o... uw.. irzrl] .,P xo K. w I fJ: ;Y. Itii�Ll fl �t_.iaLF_ F.Y MMKw Q`. �.TIP .. �. W.xW,w :x.WWW: DETAIL-. n.uPW ®�wu]�MIY �.i.l•.wI�P. eVLAW..•.(Y �sW ]..tt ILII Ili ©~MWl .Mw.x auWs nRaw..Rx �nsW� � I, oho:,. i At -1. ..K�tl LT.' I .W�M•��L .x,A.. -L. ©q.xWt,.,• I p x�owr000e�wa ww.c..o... uw.. irzrl] .,P xo K. w I fJ: ;Y. Itii�Ll fl ®�wu]�MIY �.i.l•.wI�P. eVLAW..•.(Y �sW ]..tt ILII Ili ©~MWl .Mw.x auWs nRaw..Rx �nsW� � I, oho:,. i At -1. ..K�tl LT.' I .W�M•��L .x,A.. -L. ©q.xWt,.,• I p x�owr000e�wa ww.c..o... uw.. irzrl] .,P xo K. w REEFERE\CE VIEW LETA11 SCGTICN B -B OETAIL I WALE LA t WALE 2;1 IIIA u SIOEST S .TES: 1. CLAIE 1. SEAQ .IS Rc I:E IFOYISE. SEAT TUI,i gInRIW.' ER0 .T, Ig S 1 WIT' LAVER A,rAC .. SEM WVE AAtEF TO EE RISETAL-ER- ERLpR !i 15 R,11 LSE SOE TO IN T.E :�.IEAIEE. MIXE SEAT L T(AIR HAPMARE 5A.m FT -LBS. 5 w E... -Y O IIE. AcruAA, mP.l¢EFI.0 wA� Iw-s 19 3 ZZE V EE oIEEEAErvt T,iE ..P, OEM, XTRA TESSUI�S1E. ORTOIPI Oai2AS SiAiRv Y. 03-11-1898 J Reliability Driven - ATTACHMENT F VEHICLE AND AXLE WEIGHTS Reliability Driverf" VEHICLE CURB WEIGHT AND GVWR LBS CURB WEIGHT 39,700 GROSS VEHICLE WEIGHT 50,000 FRONT AXLE 16,000 DRIVE AXLE 22,500 TRAILING AXLE 14,000 Reliability Driverf" ATTACHMENT G WINDOWS Reliability Driven WINDOWS WINDSHIELD The windshield shall be designed an installed to minimize external glare as well as reflections from inside the coach. When the coach is operated at night with the passenger interior lighting on, essentially no reflections shall be visible in the windshield immediately forward of the drivers barrier. Reflections in the remainder of the windshield shall be minimized, and no reflection of any part of the coach interior behind the driver's barrier shall be visible in the windshield. The windshield shall be easily replaceable by removing zip -locks from the windshield retaining moldings. Bonded windshields shall not be used. The glazing material shall have single density tint. DRIVER'S SIDE WINDOW The driver's side window section shall be divided vertically and the rearward section shall slide fore and aft in tracks or channels designed to last the service life of the coach. The driver's side window shall not be bonded in place and shall be easily replaceable. The glazing material shall be nominal 0.25 inch (6 mm) laminated, tempered glass with single density tint, the same as the windshield. The side window shall be rated AS -2. PASSENGER SIDE WINDOWS Eight large frameless rectangular passenger side windows shall be provided on each side of the 45 foot coaches. The glazed panel outside dimension size will be 36.125 x 57.625 inch (918 x 1466.5 mm) x .188 -inch (4.76 -mm) thick. The windows will have a nominal 32 x 52 -inch (813- x 1,321 -mm) clear opening within the inner support frame structure. The side passenger windows will be double -glazed construction, hermetically sealed, AS -3 laminated float, 76% heat -absorbing laminated safety glass with light and solar transmittance of 24%. A painted aluminum sash molding will be installed along the bottom length of the passenger side windows. All windows shall be top hinged with push out at the bottom, with the exception of the wheelchair lift door and lavatory windows which do not open. All top -hinged windows shall be emergency escape type and include a single motion release bar running the entire width of the window at the lower edge to permit emergency egress. Emergency operating instructions shall be provided at each seat position for operating the push -out window. D Series Maintenance Manual GENERAL DESCRIPTION I� 1 Figure 1. Front Windshields The coaches are fitted with extra large LH and RH front windshield. The driver's side sash and passenger sash are installed along the sidewalls of the coach. En- trance door upper and lower window glazings are also incorporated. Passenger driver's and upper entrance door sash have black anodized aluminum frames. Components Windshield The LH/RH AS -1 laminated safety glass windshield halves are identical, with the exception of tinting. The windshield is laced to a flange around the openings by means of a one-piece black rubber extrusion and rub- ber locking strips. Driver's Window Date September 2013 Page 3E2-3 11291 Figure 2. Driver's Window Item Description 1 Black Anodized Aluminum Frame 2 Slider Glass The driver's double or single -glazed side window is mounted to the sidewall opening by an inner retaining frame. This window incorporates a slider -type window section at the lower front corner for tolls, signaling, or mirror adjustment. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 3E2-4 D Series Maintenance Manual Entrance Door Sash & Transom Passenger Sash 10611 Figure 3. Entrance Door Item Description 1 Transom 2 Upper Sash 3 Entrance Door 4 Lower Sash The entrance door, double -glazed upper sash, is mounted to the upper door panel by an inner retaining frame. The lower door panel has Lucite glazing. An up- per transom window is fitted above the door. The passenger sash consists of double -glazed, fra- meless glass (the inner pane is laminated, the outer pane is tempered). Each window may be pushed out for emergency escape by lifting the release bar at the lower edge of the window to disengage the safety latches. Emergency operating instructions on metal plates are attached to the release bars at each seat lo- cation. Windows directly behind the sliding wheelchair door cannot be opened. NOTICE Emergency operating instructions on metal plates are attached to the release bars at each seat location. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 ®Date September 2013 D Series Maintenance Manual Page 3E2-5 Windshield Blind Assemblies Figure 4. Windshield Blind Assemblies 654 Item Description 1 Bracket 2 Guile Rod 3 Bottom Guile Rod Support Bracket 4 Motorized Blind Assembly 5 Wiring Harness 6 Manual Blind Assembly w/Cord Up/Down Blind Rocker Switch Assembly Copyright 2013 - Motor Coach Industries Inf1, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 3E2-6 MAINTENANCE Window Cleaning D Series Maintenance Manual Wash and rinse water must be free of solids. Recir- culating auto -washing systems must be properly de- signed, maintained, and monitored for efficiency. Brush pressure should be as low as possible. The coach should never be stopped while in contact with the brushes. Conventional techniques may be used to clean windows. Use a clean, soft, unsized doth. Wet the sur- face with cleaning solution before wiping. To remove paint, ink marks, and graffiti that is re- sistant to cleaners, use a soft cloth saturated with iso- propanol or an aliphatic hydrocarbon solvent. Do not use abrasive cleaners. Avoid using razor blades or oth- er sharp instruments that might gouge the surface. Windshield Inspection The following procedure has been provided to check windshield glass, windshield openings, and cen- ter post for proper curvatures. The windshields are installed into a flange around the opening and held in place with a one-piece rubber molding. Proper installation is necessary to reduce or pre- vent stress. Glass from different manufacturers may vary in size and shape. Check non -MCI windshields for proper size and curvature. The rubber seal allows for a 5/16 in. (8 mm) difference in windshield curvature. Windshield Curvature Inspection 1. Place 3/8 in. (9.5 mm) spacers (rubber or wood) in the bottom of the windshield opening. 2. Place windshield in the opening. There should be a 3/8 in. gap all the way around, between the windshield and the body chan- nel. The glass must be square in the open- ing. if there is not a 3/8 in. space around the glass, remove material from the body flange to obtain the proper clearance. If the glass is not square in the opening, place the other glass in its opening to be sure the openings have the same degree of distortion. Driven 11292 Figure 5. Checking Windshield Curvature Item Description 1 Windshield Center Post Edge 2 Measure Midpoint Curvature 3 Cardboard 4 Chalkline 3. The center post should have the same bow as the curvature of the glass. This can be checked by carefully placing the glass (cen- ter post edge down) on a piece of card- board. With a chalk line, strike a line across from edge to edge on the cardboard. At the mid -point, measure the distance from the line to the glass. Both windshields should have the same bow. 11293 Figure 6. Checking the Bow of the Windshield Center Post hem Description 1 halkline 2 Measure Midpoint Curvature Copyright 2013 - Motor Coach Industries Ind, Inc. and its subsidiaries. All Rights Reserved, P/N 03-26-0219 D Series Maintenance Manual Driven 4. Hold the line at the top of the post (interior of the coach) and pull tightly to the bottom of the post (at the same points that the glass reaches). At several midway points, mea- sure the distance from the line to the post. 5. 0 the measurements are the same, replace the rubber. If the measurements are differ- ent, reshape the post to fit the glass. The post can be corrected by placing a solid wood block against the center of the post (inside or out) and using a heavy sledge hammer, striking the block to form the bow. NOTICE If all of the above checks and corrective actions have been taken, and it appears that the windshield(s) cannot be installed properly, further recommendations can be obtained from the MCI Service Control Center. Wheelchair Access Door Frameless Window Inspection 10610 Figure 7. Frameless Window 1. Apply moderate pressure to each of the 4 interior corners of the glass. 2. Ensure that the wheelchair access door fra- meless window installation is secure. A CAUTION Date September 2013 Page 3E2-7 If any section of the wheelchair door window shows any movement, contact MCI Service Center immediately at 1-800-241-2947 for further Instructions. Failure to follow this procedure may result in damage or loss of the window. 3. If window is secure, it must be inspected on a regular basis. Refer to Section 10 for in- tervals. Glass Removal and Installation Windshield Removal and Installation Proper installation of the windshield is necessary to reduce or prevent stress during coach operation. Since glass from manufacturer to manufacturer may vary in size and shape, windshields from a source other than MCI should be checked for proper size and curvature using the Windshield Curvature Inspection proce- dure. Read the entire procedure before starting. 1 Windshield removal and installation must be Performed by more than one person. To avoid personal Injury, wear protective gloves when handling the windshield or windscreen glass. NOTICE The tear -resistant windshield rubber seal (fence) allows for a maximum 5/16 in. (7.9 mm) difference in windshield curvature. 1. Remove the windshield wiper arm(s) and blade(s). 2. Remove the fascia molding to expose the lower windshield rubber seal. NOTICE Locking strips need to be removed from only around the windshield, unless there have been repeated problems with stress cracking the windshield(s). Then both the right-hand and left- hand windshields and the windscreen must be removed. Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 3E2-8 D Series Maintenance Manual Reliobility, Dirl 3. Remove the rubber locking strips from the bottom, side, center post, and across the top of the windshield. 4. From inside the coach, one person should push out at the top of the windshield, until clear of the seal. A person on the outside then lifts the windshield up and out of the bottom of the windshield seal. NOTICE Before proceeding with the installation of a new windshield glass, especially after a front end collision has occurred, it is recommended that the Windshield Curvature Inspection procedure be reviewed. If the opening(s) have at least a 3/8 In. (9.5 mm) gap all around square with the glass edges and the bow of the post is the same as the new glass's curve as checked, then proceed. 5. If collision damage has occurred, remove the seal and make an inspection. Gently clean and inspect all surfaces of the opening before reinstalling the rubber seal material. 6. Soak rubber seal (fence) in warm soapy wa- ter and reinstall into the opening. 7. When driving the rubber onto the center post, support the post from the opposite side to prevent changing the shape of the post. 8. Be sure the rubber seats onto the center post. All the grooves should be seated in the U -channel. 9. Using a liquid lanolin hand soap, lubricate the groove and install the glass into the rub- ber seal. 10. Carefully place the glass, bottom first, into the rubber seal groove. With the windshield installed, check to see if the lacing tool will slide through the lacing channel. R the lac- ing tool binds, shift the windshield until it does not bind. 11, Lubricate the groove in which the locking strip sits to help the lacing tool move through the groove. Do not stretch the lock- ing strip. NOTICE In extreme cases, the upper windscreen glass may need to be removed In order for the windshield to be properly reinstalled. If the top LH and RH corners of windshield glass bind at installation, grind the bottom of the windscreen glass to allow for needed clearance. Destination Sign Removal 1. Turn main battery disconnect switch OFF. 2. Disconnect cables from sign. 3. Unfasten bracket -to -sign mounting hard- ware and free sign from front upper frame mountings. 4. Push the sign forward and maneuver one end out through the sign access door. Driver's Window Frame Removal and Installation 1. Remove all screws from the interior retaining frame. 2. Gently pry mounting frame out of opening with proper tools. NOTICE Further disassembly of the window frame may be necessary to replace slider units. 3. Reinstall in reverse order. 4. Install seal to outer skin panel. Press the seal into place in an alternating pattern, starting at diagonally opposed corners. En- sure seal is properly mounted against outer skin panel to prevent leakage. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Driver's Window Glass Removal and NOTICE Installation 1. Find the spot where the two ends of the Do not use Glass Slip. Glass Slip will swell and retaining rubber meet and pry one end out. soften windshield rubber. Place 2 in. (50.8 mm) 2. Pull inner rubber retainer away from glass pieces of locking strip in the bottom center and unit. both bottom corners. Place 2 in. pieces in the center of both sides. These strips will keep the 3. Loosen the glass unit from the outer rubber glass centered as it is installed. seal and remove the glass. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Reliability Driven Date September 2013 D Series Maintenance Manual Page 3E2-9 4. Soak retainer rubber in warm soapy water and install glass in reverse order. Use rub- ber mallet as necessary. Entrance Door Upper Sash Removal and Installation 1. Remove the inner screw covering rubber. 2. Remove the screws retaining the inner frame to the outer locking frame and re- move. 3. Remove the outer locking frame with glass unit. 4. Reinstall sash frame and window in reverse order. Ensure proper placement of seal to outer door panel to prevent leakage. Entrance Door Lower Lucite Window Removal and Installation 1. Remove the inner door panel to access locking strip. 2. Removing locking strip from inner rubber seal. 3. Gently push window out of rubber seal to- ward inside of coach. 4. install window into seal rubber. 5. Lubricate locking strip groove and reinstall strip. 6. Reinstall panel in reverse order. Entrance Door Transom Window Removal and Installation 1. Insert small flat -bladed tool into outer locking seal and gently work locking seal apart all around window. 2. Unfold the locking rubber seal to remove window. 3. Install window into seat and retold the lock- ing rubber seal. 4. Apply warm soapy water to the locking rub- ber and reseal using rubber mallet. Passenger Side Sash Frame Removal and Installation I Passenger sash frame removals and installations must be performed by more than one person. 1. Remove all screws from the interior retaining frame. 2. Gently pry mounting frame out of opening with egress frame attached. 3. Reinstall sash frame in reverse order. En- sure proper placement of seal to outer skin panel to prevent leakage. Passenger Side Sash Egress Frame Removal and Installation 1. Remove the screws and retainer clips from the hinges. 2. Swing the window out tar enough to disen- gage the frame extrusions and remove. 3. Reinstall in reverse order. Passenger Side Sash Glass Removal and Installation 1. Find the spot where the two ends of the retaining rubber meet and pry one end out. 2. Pull inner rubber retainer away from glass unit. 3. Loosen the glass unit from the outer rubber seal and remove the glass. 4. Soak retainer rubber in warm soapy water and reinstall glass in reverse order. NOTICE All side window glass units on a given coach are Interchangeable with one another. Single and double -glazed glass use different interior retaining rubber seals. Passenger Side Sash Egress Release Bar Removal and Installation 1. Drill out rivets attaching release bar to egress frame hinge assemblies. 2. Mount new release bar to hinge and rivet to- gether. Copyright 2013 - Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 3E2.10 D Series Maintenance Manual Reliablllly Driven SPECIFICATIONS DRIVER'S WINDOW ASSEMBLY Manufacturer.............................................................................................................................................Atwood Mobile PASSENGER SASH ASSEMBLY Manufacturer.............................................................................................................................................Atwood Mobile SERVICE TOOLS SOME OF THE TOOLS USED FOR MAINTENANCE PROCEDURES OUTLINED IN THIS SECTION ARE NONSTANDARD. THEY ARE, HOWEVER, AVAILABLE FOR PURCHASE THROUGH MCI SERVICE PARTS. WHERE PRACTICAL, THEY MAY BE FABRICATED AT THE SERVICE FACILITY. 20 - NPN1703: Lacing Tool, 9/16 -in. Eye Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Reliability Driverf ATTACHMENT H AXLE INFORMATION Reliability Driven - VEHICLE CURB WEIGHT AND GVWR LBS CURB WEIGHT 39,700 GROSS VEHICLE WEIGHT 50,000 FRONT AXLE 16,000 DRIVE AXLE 22,500 TRAILING AXLE 14,000 Date September 2013 oma D Series Maintenance Manual Page 1A-1 SECTION 1 A FRONT AXLE CONTENTS OF THIS SECTION SUBJECT PAGE GENERAL DESCRIPTION ............................................. 1A-4 Components.....................................................1A-4 PartsCleaning ................................................... 1A-5 Inspections and Measurements ..................................... 1A-5 Steering Knuckle ................................................. 1A-5 Installation......................................................1A-14 Adjusting the Toe -In .............................................. 1A-14 Removing the Tie Rod Assembly .................................... 1A-15 Corrosion Protection for New Parts .................................. 1A-16 Unitized Wheel End (UWE) Inspection ................................ 1A-16 Lubrication......................................................1A-17 Adjustments.....................................................1A-18 Alignment.......................................................1A-19 TROUBLESHOOTING................................................ 1A-22 SPECIFICATIONS................................................... 1A-22 TORQUE CHART .................................................... 1A-23 Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PIN 03-26-0219 Date September 2013 W D Series Maintenance Manual Page 1A-3 r Driven Figure 1. Front Axle Assembly with Disc Brakes 43634 Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 1A-4 D Series Maintenance Manual Rellabiliry GENERAL DESCRIPTION NOTICE Generic illustrations used in this section show maintenance procedures for axle components; other components are representational, and may differ from actual configuration. The D series coach uses the Meritor Easy Steer type front axle assembly. This section addresses the general and specific maintenance requirements for the front axle steering related components. Front end alignment specifica- tions and procedures are included in this section. Refer to applicable sections of this maintenance manual for information on brake assemblies, hubs, and other wheel end components. FH I 941 EX � '21 J 25 42144 Figure 2. Axle Identification Plate Rem Description 1 Axle Model Number 2 Brake Type 3 Variation Components The front axle assembly is complete with steering arm, tie rod assembly, brake assembly, hubs, discs, wheel end bearings, and bearing/bushing seal compo- nents. Axle The front axle is a forged steel, reversed Elliott style, straight -axle design. Front axles have nonadjust- able zero (neutral) camber, caster, and knuckle pin in- clination angles. I Do not repair the axle beam or knuckles. These components are heat-treated and tempered. Failure to replace damaged or out -of - specification components is unsafe and voids the warranty. Always wear eye protection when performing vehicle maintenance or service. Do not weld any steering or axle components. Do not bend knuckles or any steering or axle components. Do not drill out the king pin holes. Do not drill out draw key holes. Do not spray weld bearing or bores. Always follow manufacturer's instructions when using cleaning solvents, hot solution tanks, and alkaline solutions. Do not use gasoline to clean parts: gasoline can explode. I Do not attempt straightening of the axle. Any manipulation of or alteration to the axle could severely affect load rating and drive ability. Tie Rod Assembly The tie rod assembly connects the steering knuck- les through tie rod mounting arms, threaded tie rod ends, and clamps which provide and maintain correct axle steering geometry. The tie rod assembly has a center section and sealed replaceable ends. Adjust- ments to toe -in are made by turning the center section of the tie rod assembly. Steering Knuckles Steering knuckles are attached to the axle ends with straight king pins and retained by a set of draw keys. Knuckles are fitted with special king pin bush- ings. King pin bushing covers, spacers, and seals pre- vent dust and moisture from entering bushings. Stop screws installed on each knuckle assembly limit turning angle of the front wheels. Knuckles mount all steering and wheel end components (i.e., tie rod arms, drag link steering arm, brakes, hubs, bearings). Steering knuck- le spindles are tapered and are equipped with the Unit- ized Wheel End (UWE) and Pro-Torq@ nut. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Reliability Driven D Series Maintenance Manua! Page 1A-5 Parts Cleaning Axle Inspection Cleaning Ground or Polished Parts Periodically inspect all mounting fasteners to as - Use cleaning solvent to clean ground or polished sure proper torques as listed in the specification at the end of this and other sections. Conduct visual axle in - parts and surfaces. Kerosene and diesel fuel can be spections to check for any obvious damage, distortion, used for this purpose. Do not use gasoline. of fatigue cracks. Cleaning Rough Parts Rough parts can be cleaned with the same sol- vents as ground and polished parts. Rough parts can also be cleaned in hot solution tanks with weak alkaline solution. The parts must stay in the hot solution tanks until they are completely cleaned and heated. Drying Cleaned Parts Parts must be dried immediately after cleaning. Dry the parts with clean paper towels, rags, or compressed air. Do not dry bearings with compressed air. Corrosion Prevention on Cleaned Parts Apply light oil to undamaged, cleaned and dried parts that are to be assembled immediately. DO NOT apply oil to pads. If parts are to be stored, apply a cor- rosion inhibitor to all surfaces. Do not apply corrosion inhibitor to pads. Store parts in paper or other corro- sion -preventive material. NOTICE Ensure that all tapered parts are clean and dry, with no lubricant or corrosion preventive applied to mating surfaces. Inspections and Measurements General and Routine Inspections (Refer to Section 10 for intervals.) 1. Replace worn or damaged fasteners. 2. Ensure that all fasteners are tightened to correct specifications. (See TORQUE CHART in this section.) 3. Inspect the axle and axle parts for wear or damage. 4. Check for any bent or cracked parts. 5. Inspect the tires for wear patterns that indi- cate suspension damage or misalignment. 6. Replace all worn or damaged parts. 7. Ensure there is no excessive play or binding in any pivot point. 1 . Any damaged axles or axles with cracks should be immediately removed from service and replaced. NOTICE Magnetic particle (magnaflux) examinations or dye penetrant Inspections can be performed to check for nonvisual cracks. Steering Knuckle Figure 3. Steering Knuckle Components Item Description 1 Spindle 2 Upper Draw Key 3 King Pin 4 King Pin Caps 5 Steering Arm 6 Axle 7 Lower Draw Key 8 1 Tie Rod 9 Tie Rod End Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 1A-6 D Series Maintenance Manual �,. Steering knuckles, king pins, and bushings may be serviced or replaced without removing the axle from the coach. The axle to steering knuckle pivot joint utiliz- es straight knuckle king pins. NOTICE These measurements are made with the wheel bearings tightened on the spindle. MF�T� bushings installed, the range of side-to-side tire move- ment should not exceed 0.01 (0.25 mm) maximum. End play is the free movement of the steering knuckle up and down along the axis of the king pin. Some end play is required to prevent binding of the knuckle while turning and to provide a passage for grease to purge during bushing lubrication. Excessive end play can cause interference between the king pin and end caps or retainers. Shims are used to limit the vertical movement of the knuckle with respect to the axle center and king pin. Carefully inspect shims, new or used, to be sure none are kinked, bent, or torn. Dis- card any that are damaged. Select a quantity of shims to obtain as little vertical end play as possible. Wear gloves when holding shims. Shims have sharp edges. Inspection Knuckle end play can be measured without hubs, brake spiders, wheels and tires during rebuild as out- lined in Procedure 1, or with the axle in service as in 10784 Procedure 2. Figure 4. Side -To -Side Tire Movements with New and Worn King Pin Bushings A. New Bushings B. Worn Bushings Item Description 1 Max. Side -to -Side Tire Movement 0.010 in. (0.254 mm) 2 Bushing 3 Tire 4 Max. Side -to -Side Tire Movement 0.030 in. (0.762 mm) A loose steering linkage under normal steering loads is sufficient cause to immediately check all pivot points for wear. Special attention should also be given to the condition of the steering knuckle kin pins and bushings. The axle manufacturer recommends that the Easy Steer king pin bushings be replaced when the range of side-to-side tire movement reaches 0.030 in. (0.762 mm), or when the bushings are wom to a maxi- mum of 0.01 in (0.25 mm) on their diameter. With new NOTICE The use of shim gauges (feeler gauges) for measurement of clearance tolerances on steering knuckles Is not recommended. These will not give an accurate reading of end play. Use only a dial indicator. Procedure 1 (Wheel and Tire Assembly Removed) Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26.0219 Date September 2013 Reliability Driveri D Series Maintenance Manual Page 1A-7 With king pin caps removed, turn the knuckle to the straight -ahead position. Take a rubber mallet and repeatedly strike the top pin boss of the knuckle. This will shift all of the components down and remove grease layers so an accurate reading may be taken. NOTICE Attach the dial indicator with a C-clamp or magnetic base to the knuckle spindle such that the knuckle can be turned freely. Figure 6. Dial Indicator Setup Item Description 1 Dial Indicator 2 Linkage 3 Magnetic Base 4 Spindle 2. Place the dial indicator plunger on the ex- posed end of the king pin so that its line of action is approximately parallel to the king pin center line. Now, zero the dial indicator 42120 Figure 7. Measuring End Play 3. Measure the knuckle clearance (end play) by using a suitable lever to lift the knuckle while observing the dial indicator. Make a note of the measurement. 42121 Figure 8. Lifting the Knuckle 1 When using a hydraulic jack, be sure the axle is supported by two lack stands. Raising the end in this manner may causes an axle supported only in the center to tip and fall, causing personal injury. NOTICE A small hydraulic jack under a block of wood can be used beneath the knuckle to provide the necessary lift. Keep lifting the knuckle until the dial indicator reading levels off. Copyright 2013— Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 1A-8 D Series Maintenance Manual 4. Repeat steps 1-4 with the knuckle in the full right and left turn positions. This is nec- essary to ensure no binding or excessive play is present during turns. Procedure 2 (Wheel and Tire Assembly Installed) 1. Securely block vehicle to prevent rolling. 2. Place a jack under the axle beam as close as possible to the knuckle end being checked and jack the vehicle up until the tire is clear of the floor. NOTICE Attach a dial indicator to the axle beam with a C-clamp or magnetic base. 42122 Figure 9. Dial Indicator in Position 3. Place the dial indicator plunger on top of the knuckle pin cap or knuckle forging so that its line of action is approximately parallel to the king pin center line, and zero the dial indica- tor. 4. Measure the knuckle clearance (end play) by using a suitable lever to lift the knuckle while observing the dial indicator. Make a note of the measurement. NOTICE If binding exists or zero end play is measured anywhere in the full travel of the knuckle, remove shims as required to obtain end play of 0.001-0.025 in. (0.025-0.635 mm). After measuring Ddveri knuckle clearance (end play) of over 0.025 in. (0.635 mm), add shims between upper king pin boss and axle center end, as required, to obtain an end play of 0.001-0.025 In. (0.025-0.635 mm) through full range of turn. Normal seating of the bearing, seal, and shims will increase the end play reading after a short time in service. Inservice axle end play may increase to a maximum of 0.065 in. (1.651 mm) at which time it will be necessary to re - shim end play back to 0.001-0.025 in. (0.025-0.635 mm). NOTICE If a reading over 0.065 in. (1.651 mm) is taken, remove the tire and king pin cap and remeasure as in first procedure. If the reading is still over 0.065 in. (1.651 mm), shim the knuckle to within the specifications. If one bushing requires replacement, replace both knuckle bushings. Axle Beam Inner Bore 3 4/ Figure 10. Axle Beam Inner Bore Measurement Hem Description 1 Micrometer and Telescoping Gauge 2 Axle 3 Measuring Point 0.5 in. (12.7 mm) from Bottom 4 Measuring Point 0.5 in. (12.7 mm) from Top Copyright 2013— Motor Coach Industries Inti, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 �+ D Series Maintenance Manual Page 1A-9 Driven 1. With wheel assembly, tie rod assembly, and steering knuckles removed, measure the inner bore of the axle beam using an inside diameter caliper. 2. Due to surface rounding at the top and bot- tom of the beam (due to normal wear), mea- sure the axle beam bore at two specific depths: 0.5 in. (12.7 mm) below the top of the bore and 0.5 in. (12.7 mm) above the bottom of the bore and at four radial posi- tions. 3. Average the measurements. If the average exceeds the axle beam bore maximum di- ameter given in Axle Wear Limit Specifica- tions, the entire axle beam requires re- placement. 4. Inspect the tie rod arm taper for wear or damage as well as the hole for the taper in the knuckle. If the knuckle hole is worn or damaged, replace the knuckle and arm. If only the taper on the arm is damaged, re- place the arm. 5. If the king pin has worn through the bushing and into the knuckle, replace the knuckle. NOTICE If any part of the steering linkage is loose, check all the pivot points. Check the pivot points when the linkage is lubricated. 6. Make sure all steering linkage pivot points are tight. 7. Inspect the thrust bearing and seal for wear or damage. Replace any worn or damaged parts. Axle Wear Limit Specifications Maximum Diameter Knuckle Bore 1.922 in. (48.82 mm) Axle Beam Bore 1.798 in. (45.67 mm) King Pin Bushing Bore 1.795 in. (45.59 mm) King Pin Bushings t 2 42141 Figure 11. Measuring King Pin Bushing Inner Diameter Item Description 1 Micrometer and Telescoping Gauge 2 Upper Bore Measurement Point 3 Lower Bore Measurement Point 1. Measure the king pin bushing inside diameter with a micrometer and a telescoping gauge at the points indicated. 2. Make a note of the measurement. 3. Rotate the gauge 90 degrees and measure again at both points. 4. Average the measurements. 5. If the average inside diameter measurement exceeds the king pin bushing maximum in- ner diameter (Axle Wear Limits Specifica- tions), install new bushings. Copyright 2013 — Motor Coach Industries Incl, Inc. and its subsidiaries. All Rights Reserved. PM 03-26-0219 Date September 2013 Page 1A-10 D Series Maintenance Manual ReNablNty Ddven Upper Knuckle Bore Remove the old bushing from the knuckle. NOTICE Measurement procedures for the knuckle bores are very similar to the procedures for bushing inner diameter measurement. 42142 Figure 12. Measuring Knuckle Bore Inner Diameter Item Description 1 Micrometer and Telescoping Gauge 2 Upper Bore Measuring Point 1 3 Upper Bore Measuring Point 2 4 Knuckle 5 Lower Bore Measuring Point 1 6 Lower Bore Measuring Point 2 2. Measure the upper knuckle bore inside di- ameter in four positions and at two loca- tions. The two locations must be 90 degrees opposed from each other. Always use a mi- crometer and a telescoping gauge when measuring knuckle bore inside diameter. Rounding at the top and bottom of the beam (due to normal wear) is acceptable. 3. If the average measurement exceeds the knuckle bore maximum diameter specifica- tions (Axle Wear Limits Specifications), replace the knuckle. Lower Knuckle Bore The method to measure the lower knuckle bore is identical to measuring the upper knuckle bore. Follow the steps given above for upper knuckle bore inspec- tion and use the same table for reference data. Tie Rod and Tie Rod Ends Tie rod and inspection and replacement is neces- sary to maintain vehicle alignment. Failure to replace worn tie rod ends will cause premature wear of steering and suspension components, and will affect steering. Lift the front end of the coach and Install safety stands. Do not work under a vehicle supported only by jacks. Always inspect the tie rod ends before lubrication. After lubrication, the tie rod end inspection will be compromised. ACAUTION Replace the entire tie rod end if the boot is torn or missing. Do not replace only the boot. 1. Block the rear wheels of the coach. 2. Lift the front end of the coach and install safety stands. 3. Turn the wheels to full left, then full right, then straight ahead. NOTICE The boot may be missing completely or may not completely cover the ball Joint. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 D Series Maintenance Manual Reliability Driven Figure 13. Tie Rod End Boot Item I Description i 1 Cracked or I am Boot 4- Check for secure tie rod end nuts and cotter pins. If a pin is missing, torque the nut to specification and install a new pin. Never loosen a tie rod end nut to install a cotter pin. PF!I%, A cotter pin must be installed through the tie rod end with the tie rod end nut tightened to torque specification to securely attach the tie rod. Loss of the cotter pin will allow the tie rod end nut to become loose and affect vehicle steering and possibly result in total loss of steering control. Date September 2013 Page 1 A-11 Figure 14. Missing Cotter Pin Item I Description t 1 Steering Knuckle 2 1 Missing Cotter Pin 5. Check that the tie rod nut is installed and se- cured with a cotter pin. If a pin is missing, check the nut torque specification and then install a new cotter pin. Always tighten tie rod nut to specified torque when setting the cotter pin. Never back off a nut to install a pin. A missing cotter pin indicates unsafe condition and requires immediate replace- ment. A CAUTION The tie rod ends must be at the end of the cross tube slot to ensure adequate thread engagement. NOTICE Check the tie rod end play by hand. Do not use a pry bar; the readings from the dial indicator will not be accurate and It could damage the tie rod end or give a false Indication of wear. Always inspect the tie rod ends before lubrication. After lubrication, the tie rod end inspection will be compromised. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 t� _ z Figure 14. Missing Cotter Pin Item I Description t 1 Steering Knuckle 2 1 Missing Cotter Pin 5. Check that the tie rod nut is installed and se- cured with a cotter pin. If a pin is missing, check the nut torque specification and then install a new cotter pin. Always tighten tie rod nut to specified torque when setting the cotter pin. Never back off a nut to install a pin. A missing cotter pin indicates unsafe condition and requires immediate replace- ment. A CAUTION The tie rod ends must be at the end of the cross tube slot to ensure adequate thread engagement. NOTICE Check the tie rod end play by hand. Do not use a pry bar; the readings from the dial indicator will not be accurate and It could damage the tie rod end or give a false Indication of wear. Always inspect the tie rod ends before lubrication. After lubrication, the tie rod end inspection will be compromised. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page to -12 i\ �T - -- '-I 3 2 D Series Maintenance Manual Figure 15. Tie Rod and Cross Tube 6. Mark the position of the tie rod. Check that the tie rod end is threaded correctly into the cross tube and engaged deeper than the end of the cross tube slot. The tie rod and must be visible the entire length of the cross tube slot. 7. Check that the zerk fittings are installed. Re- place a damaged zerk fitting with a new one. Some tie rod ends are non-greaseable and will not have zerk fittings. Do not install fit- ting if tie rod end is non-greaseable type. ACAUTION Do not use the following items or methods to check for movement of the tie rod assembly. Damage to the components can result if: • A crow bar, pickle fork or a 2x4 is used. • A tool instead of your hands is used to grasp the cross tube assembly that results In cross tube damage. • Pressure or force is applied to the ends or the joints of the assembly. • The tires are rocked either with the vehicle on the ground or with the wheels raised. NOTICE If replacement is necessary, replace both tie rod ends at the same time. 6. If any movement is detected at either tie rod end, replace both ends. Drivers Roadside Tie Rod Assembly Replacement According to D.O.T., any detectable movement when checking by hand of 118 in. (3 mm) or more, re- quires the vehicle is immediately taken out of service for replacement of the tie rod ends. When the roadside check indicates tie rod end movement of less than 1/8 in. (3 mm), the vehicle does not need to be immediately removed. The vehicle should be scheduled a major out -of -service inspection and maintenance as soon as possible. Shop Inspection 1 . Check the tie rod boot for cracks, tears or other damage. All tie rod ends with a damaged boot require that the entire be rod end be replaced. 2. By hand or using a pipe wrench, with jaw protectors to avoid gouging the cross tube, rotate the cross tube toward the front of the vehicle and then toward the rear. kT 1� 2 Figure 16. Tie Rod Inspection Item Description t Push Up 2 Pull Down Copyright 2013 - Motor Coach industries Ind, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 @em Description 1 Engaged Property 2 Tie Rod Threads Visible 3 Tie Rod Cross Tube Slot End 6. Mark the position of the tie rod. Check that the tie rod end is threaded correctly into the cross tube and engaged deeper than the end of the cross tube slot. The tie rod and must be visible the entire length of the cross tube slot. 7. Check that the zerk fittings are installed. Re- place a damaged zerk fitting with a new one. Some tie rod ends are non-greaseable and will not have zerk fittings. Do not install fit- ting if tie rod end is non-greaseable type. ACAUTION Do not use the following items or methods to check for movement of the tie rod assembly. Damage to the components can result if: • A crow bar, pickle fork or a 2x4 is used. • A tool instead of your hands is used to grasp the cross tube assembly that results In cross tube damage. • Pressure or force is applied to the ends or the joints of the assembly. • The tires are rocked either with the vehicle on the ground or with the wheels raised. NOTICE If replacement is necessary, replace both tie rod ends at the same time. 6. If any movement is detected at either tie rod end, replace both ends. Drivers Roadside Tie Rod Assembly Replacement According to D.O.T., any detectable movement when checking by hand of 118 in. (3 mm) or more, re- quires the vehicle is immediately taken out of service for replacement of the tie rod ends. When the roadside check indicates tie rod end movement of less than 1/8 in. (3 mm), the vehicle does not need to be immediately removed. The vehicle should be scheduled a major out -of -service inspection and maintenance as soon as possible. Shop Inspection 1 . Check the tie rod boot for cracks, tears or other damage. All tie rod ends with a damaged boot require that the entire be rod end be replaced. 2. By hand or using a pipe wrench, with jaw protectors to avoid gouging the cross tube, rotate the cross tube toward the front of the vehicle and then toward the rear. kT 1� 2 Figure 16. Tie Rod Inspection Item Description t Push Up 2 Pull Down Copyright 2013 - Motor Coach industries Ind, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 W D Series Maintenance Manual Driven 3. From directly below the tie rod end, with both hands, grab the tie rod as close to the end as possible, no more than 6 in. (152.4 mm). Apply hand pressure [approxi- mately 100 lbs (45.4 kg)] up and down sev- eral times. Check for any movement or looseness at both tie rod end locations. 17%,71-1 . If any movement is detected by hand, replace the worn components with new components before releasing the vehicle back into service. 4. If any movement is detected at one tie rod end, replace both tie rod ends. Always re- place tie rod ends in pairs, even it only one tie rod is found damaged. I Do not attempt to straighten a bent cross tube. Damage to the axle can result. Be certain to replace any cross tube with an original equipment cross tube (with the same length, diameter, and threads). Figure 17. Cross Tube and Clamps Mem Description 1 Cross Tube Clamp 2 I Crack Damage 5. Inspect the cross tube and damps for dam- age. • Replace the cross tube 8 it is cracked or bent. • Replace the clamps if any are damaged. • Replaced the entire cross tube assembly if either damp is welded onto it. Date September 2013 Page 1A-13 10256 Figure 18. Tie Rod and Cross -Tube N a Item Description 1 5ngaged Properly 2 Tie Rod Threads Visible 3 Tie Rod Cross -Tube Slot End Check for proper installation it the tie rod end clamp to the cross tube. Be certain that tie rod ends are threaded in the cross tube past the clamps and the slots at the cross tube ends. Check that zerk fittings are installed. Re- place damaged zerk fittings. Some tie rod ends have no zerk fittings be- cause they are not greaseable. Do not in- stall a zerk fitting on a non-greaseable de- sign tie rod end. Check that the cotter pin is in place, replace if missing. Tighten the tie rod end nut to the specified torque and then insert the cotter pin through the castellated nut and the hole in the fire rod end. Zerk Fittings Figure 19. Zerk Fitting Item Description 1 Alternate Zerk Fitting Locations Copyright 2013 - Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 ��1ir1 Page 1A-14 D Series Maintenance Manual Reliability Driven 1. if a zerk fitting is missing, install a new one. Do not attempt to install a fitting if the tie rod end is a non-greaseable design. 2. Tighten all zerk fittings to the specified torque. Installation Installing the Tie Rod Ends into the Cross Tube I To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. I Do not bend, weld, or heat front axle components. NOTICE The cross tube has right-hand threads on the right side of vehicle and left-hand threads on left side of vehicle. Make sure the tie rod end threads are correctly installed into the tube deeper than the cross tube slot. 1. If you are only replacing the cross tube: When replacing the cross tube, be certain that the replacement cross tube is properly specified from OE manufacturing standards. The replacement tube should have the same length and diameter as the original (removed) tube that couples with the tie rod ends. Use the thread count as a guide and install the tie rod ends into the threaded cross tube ends to the approximate depth marked during the tie rod assembly removal. Both tie rod ends must be installed into the cross tube deeper than the end of the cross tube slot. 2. If you are installing new tie rod ends: Thread the tie rod ends to the approximate original depth in side the cross tube. Both tie rod ends must be installed into the cross tube deeper than the end of the cross tube slot. 3. Install the nuts and bolts in the clamps. Tighten to the specified torque. (See TORQUE CHART in this section.) 4. Ensure the tab on the clamp is firmly seated against the end of the cross tube. Installing the Tie Rod and Cross Tube Assembly onto the Axle 1 . Clean and dry the tie rod and taper and the tie rod arm taper hole. Connect the tie rod ends into the cross tube beyond the end of the slot. 2. Push the threaded tie rod and through the knuckle tie rod arm hole. 3. Loosely install both lie rod end nuts to se- cure the tire rod end and cross tube assem- bly linkage to the tie rod arm. 4. Tighten the tie rod end to the specified torque. (See TORQUE CHART in this sec- tion.) NOTICE Do not loosen the nut to install the cotter pin. 5. Install the cotter pins. If necessary, tighten the lock nut until the holes area aligned. 6. Check and adjust the toe -in. See Adjusting the Toe -In in this section. Adjusting the Toe -In Numerous methods are available to check and ad- just toe such as lasers and electronic measuring devic- es. the following is a simple system, when used proper- ly, will result in satisfactory toe adjustment. j • To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. "Toe" is the relationship of the distance measured between the front centerline of the front tires and the rear centerline of the front tires. When the front distance is less than the rear dis- tance, the wheels are "toed -in". Toe -in is designed into the vehicle to counteract the tendency of the tires to toe -out when the vehicle is driven. Incorrect toe adjustment will result in uneven and excessive inner or outer tread wear. Copyright 2013—Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 D Series Maintenance Manual Page 1A-15 NOTICE Do not measure toe -in with the front axle in the raised position. The weight of the vehicle must be on the front axle when toe -in Is measured. Toe -in Specification I Incorrect toe settings affect tire wear. Do not change camber or caster settings to correct tire wear problems. If the axle assembly is bent to change caster or camber, the strength of the axle Is reduced and the warranty is voided. An axle will be damaged by bending and may cause a vehicle accident resulting in serious personal injury. rVIVONGM Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury can result. i. The vehicle must be on a level surface. Place blocks behind the rear wheels to prevent the vehicle from moving. 2. Use jacks to raise the vehicle so that front tires are off the ground. Support the front axle with safety stands. 3. Use paint or chalk to mark the center area of both front tires around the complete outer tread surface of the tire. 4. Place the pointers of a trammel bar on the marks of each tire. rotate the tires. Make sure a straight line is marked on the outer surface of the tire. 5. Before lowering the vehicle to the ground, place turn plates (slip plates) directly under the front tires to relieve any bind in the steer- ing system and ensure correct readings/ad- justment. If turn plates are not available, plastic wrap for packaging can be placed between tires and ground surface. Lower the vehicle. 6. Place the trammel bar at the back of the tires. Raise the pointers so the pointers are level with the spindles. Align the pointers with the marks on the tires. Measure and re- cord the distance between the pointers. 7. Place the trammel bar at the front of the tires. Raise the pointers so the pointers are level with the spindles. Align the pointers with the marks on the tires. Measure and re- cord the distance between the pointers. 8. To obtain the toe measurement, subtract the distance reading between the front of the tires from the distance reading between the back of the tires. g. It the toe measurement is not at the speci- fied distance, perform the following proce- dure: a. Loosen the tube clamp nut and bolt on each end of the cross tube. b. Turn the cross tube until the specified toe -in distance is obtained. C. Check that both tie rod ends are threaded correctly into the cross tube and engaged deeper than the end of the cross tube slot. The tie rod threads must be visible the entire length of the cross tube slot. d. Tighten the nut and bolt on each end of the cross tube to the specified torque. Refer to Tie rod Assembly Torque Specifications. 10. Repeat steps 1-8 to check the toe -in di- mension. Removing The Tie Rod Assembly I To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. 1 . Remove the cotter pins and the nuts on both sides of the axle that fasten each tie rod end to the tie rod arms. 2. Disconnect the cross tube assembly from the tie rod arms. The use of a tie rod end puller is recommended, if available. If necessary, tap on the tie rod end with a leather or plastic mallet to loosen the tie rod end tram the tie rod arm. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PM 03-26-0219 Tie Rod End Removal from Cross Tube Remove the tie rod ends from the cross tube using the following procedure: 1. Remove the bolts and the nuts from the clamp on the cross tube. 2. If replacing only the cross tube, mark the in- stalled position of each tie rod end. Count and record the number of threads that ap- pear outside of the cross tube. A CAUTION Do not remove clamps that are welded to the cross tube. Removing welded clamps will damage the cross tube. 3. Remove the threaded tie rod ends from the cross tube 4. Inspect the parts for damage. 5. When replacing the cross tube, be certain the replacement cross tube is properly spec- ified from OE manufacturing standards. The replacement tube should have the same length and diameter as the original (re- moved) tube that couples with the tie rod ends. i To prevent serious eye Injury, always wear safe eye protection when you perform vehicle maintenance or service. Corrosion Protection for New Parts NOTICE Do not apply lubrication or a corrosion -preventive material to the tie rod taper mating surface. Apply a light oil to cleaned parts that will be immediately assembled. Taper must be clean and dry when assembled. 1. Carefully inspect the disassembled tie rod ends and cross tube before assembly. 2. Replace any parts that are worn, cracked, or damaged. 0810014 if necessary, use dye penetrant, magnetic flux, or fluorescent testing methods to check the cross tube for cracks. Replace the cross tube if cracks are detected. If replacement is necessary, replace both tie rod ends at the same time. Unitized Wheel End (UWE) Inspection The Unitized Wheel End (UWE) is a non -service- able, complete hub assembly that uses a prelubricated and sealed bearing assembly. However, it needs to be checked regularly for bearing condition. Refer to Sec- tion 15 - Wheels, Hubs, and Tires for UWE Inspection procedures. The hub assembly is composed of a wheelend adapter, rotor, and unitized hub bearing mounted to the spindle. The bearing assembly requires no maintenance and is not adjustable. Periodic inspec- tion is required to maintain performance. Refer to Sec- tion 15 - Unitized Hubs (UWE) for more information regarding inspection. Inspection As with all other bearing assemblies, rotate the hub assembly while checking for noise or rough operation. Check end play of the bearing assembly as described above. Any roughness, noise, or end play will require that the bearing assembly be serviced. Adjustment NOTICE Always consult the appropriate maintenance manual for your coach for exact specifications and procedures. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 8 Page 1A-16 D Series Maintenance Manual Reliabil ty Driven 2. If any parts will be stored, apply a corrosion - 1 preventive material to all surfaces. Store Always support the tie rod assembly so it does parts inside special paper or other material that will prevent corrosion during storage. not fall and become damaged or cause personal injury when separated from the steering knuckles. Inspecting Parts Tie Rod End Removal from Cross Tube Remove the tie rod ends from the cross tube using the following procedure: 1. Remove the bolts and the nuts from the clamp on the cross tube. 2. If replacing only the cross tube, mark the in- stalled position of each tie rod end. Count and record the number of threads that ap- pear outside of the cross tube. A CAUTION Do not remove clamps that are welded to the cross tube. Removing welded clamps will damage the cross tube. 3. Remove the threaded tie rod ends from the cross tube 4. Inspect the parts for damage. 5. When replacing the cross tube, be certain the replacement cross tube is properly spec- ified from OE manufacturing standards. The replacement tube should have the same length and diameter as the original (re- moved) tube that couples with the tie rod ends. i To prevent serious eye Injury, always wear safe eye protection when you perform vehicle maintenance or service. Corrosion Protection for New Parts NOTICE Do not apply lubrication or a corrosion -preventive material to the tie rod taper mating surface. Apply a light oil to cleaned parts that will be immediately assembled. Taper must be clean and dry when assembled. 1. Carefully inspect the disassembled tie rod ends and cross tube before assembly. 2. Replace any parts that are worn, cracked, or damaged. 0810014 if necessary, use dye penetrant, magnetic flux, or fluorescent testing methods to check the cross tube for cracks. Replace the cross tube if cracks are detected. If replacement is necessary, replace both tie rod ends at the same time. Unitized Wheel End (UWE) Inspection The Unitized Wheel End (UWE) is a non -service- able, complete hub assembly that uses a prelubricated and sealed bearing assembly. However, it needs to be checked regularly for bearing condition. Refer to Sec- tion 15 - Wheels, Hubs, and Tires for UWE Inspection procedures. The hub assembly is composed of a wheelend adapter, rotor, and unitized hub bearing mounted to the spindle. The bearing assembly requires no maintenance and is not adjustable. Periodic inspec- tion is required to maintain performance. Refer to Sec- tion 15 - Unitized Hubs (UWE) for more information regarding inspection. Inspection As with all other bearing assemblies, rotate the hub assembly while checking for noise or rough operation. Check end play of the bearing assembly as described above. Any roughness, noise, or end play will require that the bearing assembly be serviced. Adjustment NOTICE Always consult the appropriate maintenance manual for your coach for exact specifications and procedures. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 W D Series Maintenance Manual Page 1A-17 Driverr The UWE wheel end is a nonadjustable bearing assembly. Any end play of the bearing requires that the bearing be serviced. Once the assembled UWE bearing is mounted to the spindle, the spindle nut is torqued to 600 ft -Ib. (813 Nm). Service The UWE wheel bearing assembly is a non -ser- viceable unit. Any roughness, noise or end play re- quires that the bearing assembly be replaced. Always consult your MCI Maintenance Manual or ArvinMedtor manual MM -0409 for specific information, procedures and specifications. The ArvinMeritor manu- al is available by calling MCI Customer Service at 800-323-1290. Lubrication Lubrication of the steering knuckle king pin bush- ings and tie rod ends is recommended periodically. Use lubrication specification S-16 as noted in Section 10 - Lubrication. NOTICE Inspect the boot seal periodically. Refer to Section 10 for intervals. King Pin Bushings Steering knuckles are bushed in the upper and lower pin bosses so that they may tum freely about the pins. Bushings are grooved on the inside to allow grease to flow uniformly to high-pressure areas. Grease fittings are installed at both upper and lower king pin bosses. 1. Make sure that the tires touch the ground. DO NOT RAISE THE COACH. 2. Wipe dirt and foreign material off grease fit- ting. 42128 Figure 20. King Pin Lubrication Item Description 1 Steering Knuckle 2 Top Grease Fitting 3 Axle 4 Bottom Grease Fitting 5 Grease Should Appear Here 3. Lubricate the pins through the grease fit- tings on the top and bottom king pin covers. 4. Apply lubricant until new grease oozes out between the seal of the thrust bearing and the upper shim pack. Tie Rod Ends The tie rod ends have a grease fitting located be- low the tie rod assembly. 1. Make certain the tires are touching the ground. 2. Wipe dirt and foreign material off grease fit- ting. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 1A-18 D Series Maintenance Manual E 42123 Figure 21. Tie Rod Lubrication Item Description 1 Axle 2 Tie Rod Arm 3 Tie Rod Ends 4 Grease Should Appear Here 5 Tie Rod Apply grease through the grease fittings on the as- sembly until new lubricant oozes out from the boot. Adjustments Steering Stop Adjustment The steering stop adjustment controls the vehicle's maximum turn angle. 1. Set the parking brake. 2. Loosen the jam nut on the axle's stop bolts. 3. Turn in the stop bolts. 4. Turn the wheels to the right until there is 1 in. (25 mm) of clearance between the in- side front edge of the left-hand front tire and the drag link. 2 4 3 42129 Figure 22. Steering Stop Bolt 5. Turn the right-hand knuckle stop bolt out un- til it contacts the boss on the axle beam. 6. Torque the jam nut on the stop bolt to 50-65 ft -Ib (68-88 Nm). Q CAUTION Do not increase the vehicle's maximum specified turn angle. If the angle is Increased, the steering arm, tie rod, and tie rod ends will be damaged. The hydraulic steering pressure should relieve (drop of* at the end of the steering stroke. It the pressure does not relieve, the axle components will be damaged. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Item Description 1 Steering Knuckle 2 Axle Beam Boss 3 Steering Stop Bolt 4 Stop Bolt Lock Nut 5. Turn the right-hand knuckle stop bolt out un- til it contacts the boss on the axle beam. 6. Torque the jam nut on the stop bolt to 50-65 ft -Ib (68-88 Nm). Q CAUTION Do not increase the vehicle's maximum specified turn angle. If the angle is Increased, the steering arm, tie rod, and tie rod ends will be damaged. The hydraulic steering pressure should relieve (drop of* at the end of the steering stroke. It the pressure does not relieve, the axle components will be damaged. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 0 D Series Maintenance Manual Driven" Pressure Relief Adjustment The pressure relief adjustment in the power steer- ing system stops or reduces the force applied to the steering arm when the wheel approaches full turn posi- tion. The power steering gear pressure relief valves set themselves to the steering stops the first time the coach is steered from stop to stop. Check the pressure relief if the steering arm is damaged or the power steer- ing gear is serviced. Start the engine and allow it to operate at idle speed. Full weight of the vehicle must be on the wheels. Tum steering wheel one direction until a high pressure hiss is heard or the axle stop makes contact. Turn the relief valve in or out until a high-pressure hiss is heard when there is 1/8 in. clearance between the axle stops. Repeat the procedure steering in the oppo- site direction adjusting the valve on the opposite end of the steering gear. Turning the adjusting screws in in- creases the clearance between the axle stops. Turning the adjusting screws out decreases the clearance. Re- fer to Section 11 - Steering. Alignment Correct front end alignment must be maintained for ease of steering and satisfactory tire life. Road shock, vibrations and normal stresses that are set up in the front end under average operation can result in loss of front end alignment. Refer to the following alignment data and specifications for correct adjustments. Caster, camber, and knuckle inclination are all nonadjustable on all coaches. If incorrect front end alignment is suspected, refer to the inspection proce- dure under Wheel Shimmy later in this section. Front wheel balance should first be checked to make sure that the difficulties are not originating from out -of -bal- ance front wheels or tires. Wheel installation and run out, wheel bearing adjustment, tie rod, and draglink end wear should also be considered. Correct front end alignment can be obtained and maintained only when steering knuckles are in satisfactory condition. Termi- nology and explanations for front end alignment terms are listed below: Date September 2013 Page 1A-19 1 /2 /4 42124 Figure 23. Camber Item Description 1 Vertical Axis 2 Positive Camber 3 Negative Camber 4 Zero or Neutral Camber (with Load) Front Wheel Camber: The amount the wheel leans outward (positive camber) or inward (negative camber) from the vertical plane, usually measured in degrees. All coach axles, when loaded, have Zero (Neutral) camber. NOTICE Axles are 1/4 degree positive camber in the unloaded condition, but may exhibit negative camber in some loaded conditions. Copyright 2013 - Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 1A -2o D Series Maintenance Manual 42125 Figure 24. Toe -In hem Description 1 From of Tire (Pictured mm Above) 2 Axle 3 Rear of Tire (Pictured from Above) Front Wheel Toe -In: The distance between the wheels in the front is closer than the distance between rear. The dis- tance between the tires at the rear, minus the distance between the tires at the front Is the toe -in measurement (see Adjusting Toe -In for details). Axle Caster: The fore and aft inclination from vertical of the steering knuckle. Positive caster is indicated with the top of the steering knuckle tilted toward the rear of the vehicle. Negative caster is indicated with the top of the steering knuckle tilted toward the front of the vehicle. Zero caster means no inclina- tion of the steering knuckle. All axles used on coaches have nonadjustable positive caster. Knuckle Wheel Inclination: The amount knuckle pins are inclined inward at the top. King pin inclination is nonad- justabie. Steering Geometry: The specific loca- tion and/or movement of the mechanical links that maintain correct wheat align- ment in relationship to the axle. Driven' Any manipulation or alteration to these axle characteristics could severely affect the axle's steering geometry. NOTICE All axles used on coaches have nonadjustable camber, caster, and king pin inclination angles. NOTICE Camber, caster, and toe -in settings can be found under Alignment Specifications at the end of this section. Wheel Shimmy For a variety of reasons a coach may develop a wheel shimmy at the front end. The following inspec- tion procedure is provided to help assist maintenance personnel in determining the cause of this condition. NOTICE Due to the large number of variables involved and the equipment needed to diagnose these variables, it is recommended that a reputable front end alignment shop perform the inspection and any corrections. Read and understand all steps prior to starting step one. Observe all standard and applicable safety stan- dards. 1. Check that all bolts and nuts are tight (i.e., suspension support stud nuts, U -bolt nuts, tie rod arm, steering arm nuts, etc.) and that no damage or distortion has taken place. 2. Check the steering gear for looseness and gear backlash. 3. Check the wheel balance or tires for out -of - round. 4. Check the tie rod ends for wear. 5. Check the radius rod bushings for wear. Copyright 2013 - Motor Coach Industries Int'I, Inc. and Its subsidiaries. All Rights Reserved. P/N 03-26-0219 Reliability Date September 2013 D Series Maintenance Manual Page 1A-21 6. Check for correct toe -in adjustment. 7. Check the king pin end play or king pin bushings for wear. If the bushings have 0.010 in. (0.25 mm) or more of play, they should be replaced. 8. Check for correct caster. NOTICE Excessive caster, in combination with some of the previous Items and/or in combination with road conditions, can cause wheel shimmy. A recommended 3.0 degree caster angle is achieved with the lower radius rod mounting brackets. The brackets have eyes in line with the axle center. If caster angle is less than 2.0 degrees or more than 4.0 degrees contact customer service for further instructions. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved- PIN 03-26-0219 Date September 2013 Page ,A-22 D Series Maintenance Manual _ nellobilify Driven TROUBLESHOOTING Condition Carse Correction Tires wear qulckly i. Incorrect Lire pressure 1. Inflate tires to speced pressure or exhibit uneven 2. Tires and wheels not properly balanced 2. Balance or replace tires and wheels tread wear 3. Incorrect tag axle alignment 3. Align the tag axle tandems 4. Incorrect toe -in setting 4. Adjust toe -in to the proper setting 5. Incorrect steering arm geometry 5. Service the steering system as needed 6. Excessive wheel end play 6. Adjust the wheel bearings Coach Is hard to 1. Low power steering system pressure 2. Steering gear incorrectly assembled 1. Repair the power steering system 2. Assemble the steering gear correctly steer 3. Lack of steering linkage lubrication 3. Lubricate the steering linkage 4. King pins are binding 4. Replace the king pins 5. Incorrect steering arm geometry 5. Service the steering system as needed 6. Tie rod ends are stiff 6. Replace the tie rod ends 7. Worn thrust bearing 7. Replace the thrust bearing Tie rod ends are 1. The tie rod ends need lubrication 1. Follow tie rod lubrication schedule worn 2. Damaged boot on the tie rod end 2. Replace the tie rod end Bent or broken tie 1. Adjust the power steering system to the rod, ball stud, 1. Excessive pressure in the power steering specified pressure. Verify power steering steering arm, or tie system system relief pressure. Replace pump relief rod arm valve if necessary Worn or broken 1. Drag link fasteners torqued beyond specified 1. Tighten the drag link fasteners to specified steering ball stud maximum 2. Lack of lubrication or use of incorrect torque only 2. Follow correct lubrication procedures and lubricant specifications 3. Wheel stops or relief pressure settings out of 3. Adjust the stops, or pressure relief settings, adjustment to specifications Worn king pins or 1. Worn or missing seals and gaskets 1. Replace any missing seals and gaskets bushings 2. Incorrect lubricant 2. Lubricate with the proper lubncanl 3. Axle lubrication schedule not followed 3. Follow proper axle lubrication schedule 4. Incorrect lubricating procedures 4. Follow proper lubrication procedures 5. Lubrication schedule not frequent enough 5. Increase the lubrication schedule to match for operating conditions operating conditions Vibration or 1. Wheels and/or tires are out of balance 1. Balance or replace tires and wheels shimmy in 2. Worn shock absorbers 2. Replace the shock absorbers 3. Worn radius rod bushings 3. Replace the bushings SPECIFICATIONS FRONT AXLE ASSEMBLY Manufacturer ALIGNMENT DATA (LOADED)` F7J Camber............................................................... __............. ....... ........,........... Accept" Range:0.19 to +0.68 Degrees Caster....................... _.......... ...._........ _............................ ........ ................................ ............ ........ ....3.0 Degrees Positive Toe -In (Adjustable) ...... ........... ._................................................................0.03 in. t 0.03 inch (0.794 aim t.0794 mm) Track............................ _............ _.._................................................... _.......................................... 101.82 in. (2586 mm) Copyright 2013 - Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 ill D Series Maintenance Manual page 1A-23 Ddven Figure 25. Front Axle TORQUE CHART Item Description Ft -Lb Nm 1 Draw Key Nuts 30-45 41-61 2 Threaded King Pin Caps 100-120 136-163 3 Steering Arm Nuts 775-1450 1051-1966 4 Stop Screw Locknut 50-65 68-88 5 Tie Rod Arm Nuts 550-1025 746-1390 6 Tie Rod End Clamp Locknuts 40-60 54-61 7 Tie Rod End Nuts 160-300 217-�07 Copyright 2013 - Motor Coach Industries InYI, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 alVeff D Series Maintenance Manual Page 2A-1 SECTION 2A DRIVE AXLE CONTENTS OF THIS SECTION SUBJECT PAGE GENERAL DESCRIPTION ............................................. 2A-3 Components............................................ ......... 2A-3 MAINTENANCE .............................................. .......2A-4 Inspection.......................................... .... ......... 2A-4 Axle Repair ......................................... ............. 2A-4 2A-4 Lubrication........................................ ...... ........ TORQUECHART .................................................... 2A-6 SPECIFICATIONS ............................................... .... 2A-11 Copyright 2013 —Motor Coach Industries Int'I, Inc. and its subsidiaries. Ail Rights Reserved, PIN 03-26-0219 Date September 2013 Page 2A-2 D Series Maintenance Manual Reliability Driven THIS PAGE INTENTIONALLY LEFT BLANK Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PIN 03-26-0219 D Series Maintenance Manual Driven GENERAL DESCRIPTION The drive axle is a Meritor Automotive full floating type with pressed steel housing, fitted with replaceable pressed -in steel sleeves. A magnetic drain plug is in- stalled in the bottom of the housing. The single reduction final drive employs a heavy duty hypoid drive pinion and ring gear. The differential and gear assembly is mounted on tapered roller bear- ings and lubricated by the differential oil. The straddle -mounted pinion has two tapered roller bearings in front of the pinion teeth which take the for- ward and reverse thrust, and a third bearing behind the pinion teeth to carry the radial load. Available drive axle ratios are 3.07, 3.21, 3.42, 3.73, 4.10, 4.30, and 4.56:1. NOTICE All MCI coach differentials are factory -filled with synthetic oil. Components Axle Housing Date September 2013 Page 2A-3 The hot formed rectangular axle housing is de- signed with full corner sections for strength and rigidity. The other axle components assemble to this part. Differential Carrier The single reduction carrier is front mounted into the axle housing. The carrier has a hypoid drive pinion and ring gear set, and bevel gears in the differential as- sembly. The drain plug is magnetic to catch particles that would otherwise accelerate wear. Wheel Bearings The axle shafts are fitted with oil -lubricated wheel bearings. Figure 1. Drive Axle with Disc Brakes 44293 Copyright 2013 — Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved. P/N 0326-0219 Date September 2013 Page 2A-4 MAINTENANCE Inspection D Series Maintenance Manual Refer to Section 10 for intervals. Fasteners 1. Replace worn or damaged fasteners. 2. Ensure that all fasteners are torqued to specification. (See TORQUE CHART in this section.) Wear and Damage 1. Inspect the axle and axle parts for wear or damage. 2. Look for bent or damaged parts. 3. Inspect the tires for wear patterns that Indi- cate suspension damage or misalignment. 4. Replace all worn or damaged parts. Axle Housing Repair Certain weld repairs may be made to the axle housing. Do not bend or straighten the axle housing. Damaged drive axle housings should be replaced. NOTICE Refer to the welding caution in the introductory pages of this manual before starting any welding operation. Weld repairs are only allowed on existing axle housing welds of the following types Cover welds. 2. Housing seam welds between the suspen- sion attaching brackets. a. The differential carrier and axle shafts must be removed before weld- ing to the axle housing. 3. Refer to ArvinMeritor publication number TP -9421 before welding. Lubrication NOTICE Also refer to Section 10 - Lubrication. Dnven Lubrication intervals are given for intercity coaches. For higher use coaches, gear oil must be checked and changed more frequently. Drive axle wheel bearings can be either oiled or grease lubricated dependent on coach specifications. Oil lubricated wheel bearings are lubricated by the ax- le's gear oil. For grease lubricated wheel bearings, see Hub Bearing Grease -Lubrication Intervals. Lubrication recommendations are found in Section 10 of this manual. During initial stages of normal operation, tiny metal particles are freed from mating surfaces of moving parts. These metal particles are carried by the lubricant through the assembly and act as lapping compound which accelerates wear of all parts. To ensure maximum lite of the differential and pre- vent premature failure, the original factory fill lubricant should be drained. This also prevents lubricant con- tamination by differences in factory fill and lubricant used by the operator when topping up. A, CAUTION Change break-in oil periodically. Refer to Section 10 for intervals. Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Rellobilfly lhiveri D Series Maintenance Manual Page 2A-5 Fill the Axle with Lubricant Figure 2. Drive Axle Housing Item Description 1 Fi I and it Level Plug 2 Drain Fill and drain plugs are located in the axle housing. Magnetic drain plugs perform the vital function of trap- ping small metallic particles that circulate in the lubri- cant, through the gears and bearings. They prevent rapid wear and premature failure. The magnet must be strong enough to firmly hold the particles under service conditions. We recommend plugs with elements having a minimum pick-up capacity of 2.0 Ib (0.91 kg) of low carbon steel in plate or flat bar form. Clean all magnetic drain plugs prior to reinstalla- tion. 1. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. The axle lubricant capacity changes when the drive pinion angle changes. 2. Remove the fill plug from the side of the axle housing bowl cover. 3. Add the axle lubricant through the fill plug hole. Fill the axle with the lubricant until the lubricant level is even with the bottom of the fill plug hole. Use full synthetic oil 75W-140 above -40°F (-40°C) or 75W-90 above -40°F (-40°C). 4. Install the fill plug and tighten to a minimum torque of 35 ft -Ib (47 Nm). 5. Drive the coach, unloaded, for one to two miles at speeds not to exceed 25 mph to thoroughly circulate the lubricant throughout the assembly. Recheck the lubricant levels and all of the fasteners. For reconditioned axles, follow the same proce- dures as above, after overhaul. I , Correct lubrication is critical to bearing life. If oil level is found to be low, determine the cause and correct immediately. Lack of lubrication will result in premature bearing failure resulting in dragging brakes, wheel loss, or fire. Oil Change Intervals Gear oil should be changed periodically. Use lubri- cation specification S-1 1A or S -12A as noted in Sec- tion 10. The Meritor axle drive unit employs the gravity feed (splash) system of distributing lubricant throughout the assembly. As the coach is initially driven in service, a short period of time is required for the lubricant to reach all areas of the drive units. Hub Bearing Grease -Lubrication Intervals Check periodically. (Refer to Section 10 for inter- vals.) a. Change whenever seals are replaced, b. When brakes relined, or periodically (Refer to Section 10 for intervals. If the drive axle shafts are removed for any mainte- nance or service, it is essential that the grease in the hubs be replaced in the proper quantity. To ensure that the grease lubricated drive axle hub bearings are lubri- cated after servicing and before the coach is put back into service, the following is required: Copyright 2013 - Motor Coach Industries Int'I, Inc, and its subsidiaries. All Rights Reserved. P/N 03-261-0219 Date September 2013 Page 2A-6 D Series Maintenance Manual NOTICE Use sate shop service practices at all times. 1. At rebuild, before installing the wheel bearings onto the spindle, coat the bearing journals with a film of grease to deter fretting corrosion. 2. Pack bearing with a pressure packer, if pos- sible. If a packer is not available, pack the bearing by hand, forcing the grease in the cavities between the rollers and cage from the large end of the cone. 11251 Figure 3. Drive Axle Hub Assembly Grease Level Item I Description F-1 Lube 3. Pack the hub between the two bearing cups with grease to the level of the cups' smallest diameter. Use lubrication specification S-16 as noted in Section 10. TORQUE CHART Driverf 1. The torque values in the fastener Torque Chart are for fasteners that have a light application of oil on the threads. 2. It the fasteners are dry, increase the torque values by 10%. 3. If the fasteners have a heavy application of oil on the threads, decrease the torque val- ues by 10%. 4. If you do not know the size of the fastener that is being installed, measure the fastener. Use the following procedure. American Standard Fasteners Figure 4. Determining Size of American Standard Fastener Item Description 1 Amount of Threads in ne In 2 X Dimension = (Example 1/2 in.) a. Measure the diameter of the threads in inches, dimension X. b. Count the amount of threads there are in one inch. Example of an Amer- ican Standard Size fastener is 0.50 in. -13. The 0.50 is the diameter of the fastener in inches (dimension X). The 13 is the number of threads in one inch. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Driven Metric Fasteners Date September 2013 D Series Maintenance Manual Page 2aa 11253 Figure 5. Determining Size of Metric Fastener Rem Description 1 Pitch 2 X Dimension = (Example BM or 8 mm) 3 Y Dimension = Distance of 10 Threads a. Measure the diameter of the threads in millimeters (dimension X). b. Measure the distance of 10 threads, point to point in millimeters (mm), di- mension Y. Make a note of dimen- sion Y. C. Divide dimension Y by 10. The result will be the distance between two threads or pitch. Example of a Metric size fastener is M8 x 1.25. The M8 is the diameter of the fastener in milli- meters (mm) (dimension X). The 1.25 is the distance between two threads or pitch. d. Compare the size of fastener mea- sured in Step 4 to the list of fasteners in the following chart to find the cor- rect torque value. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date Page September 2013 2A-8 D Series Maintenance Manual Figure 6. Torque Callouts 11254 Driven Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Reliability D Series Maintenance Manual Page 2A-9 Torque Values Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Torque Value Fasteners Thread Size Ft -Lb Nm 1 Capscrew, Axle Shaft 5/16-24 16-24 24-33 1/2-13 85,115 115-156 2 Nut, Axle Shaft Stud Plain Nut 7/16-30 50-75 68-102 1/2-20 75-115 102-156 5/16-18 110-165 149-224 5/8-18 150-230 203-312 Locknut 7/16.20 40-65 54-88 1/2-20 65-100 88-136 5/16-18 100-145 136-197 518-18 130-190 176-258 3 Breather 318-18 20 min. 27 min. 4 Plug, oil Filter (Housing) 3/4-14 35 min. 47.5 min. 5 Plug, Heat Indicator 1/2-14 25 min. 34 min. 6 Plug, Oil Drain 1/2-14 25 min. 34 min. 7 Capscrew, Differential Case Flange Head 318-16 35-50 48-68 Standard Hex Head 7116-14 60-75 81-102 1/2-13 85-115 115-156 9116-12 130-165 176-224 5/8-11 180-230 244-312 M12 x 1.75 85-103 115-140 M12 x 1.75 75-95 100-130 M16 x 2 203-251 275-340 8 Nut Differential Case Bolt 1/2-13 75-100 102-136 1/2-20 B5-115 115-156 5/8-11 150-190 203-258 5/8-18 180-230 244-312 M12 x 1.75 74-96 100-130 9 Nut, Ring Gear Bolt Flange Head 1/2-13 75-100 102-136 Standard Hex Head 1/2-20 85-115 115-156 5/8.11 150-190 203-258 5/8-18 180-230 244-312 M12 x 1.25 66-81 90-110 M12 x 1.75 77-85 104-115 M16 x 1.5 192-214 260-290 M16 x 1.5 190-225 260-305 10 Capscrew, Bearing Cap 9116-12 110-145 149-197 518-11 150-190 203-258 3/4-10 270-350 366-475 7/8-14 360-470 488-637 7/8-9 425-550 576-746 M 16 x 2 181-221 245-300 M20 x 2.5 347-431 470-585 M22 x 2.5 479-597 650-810 11 Nut, Housing to Cartier Stud 7/16-20 50-75 68-102 112-20 75-115 102-156 9/16-18 110-165 149-224 518-18 150-230 203-312 Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 2A-10 D Series Maintenance Manua! Torque Values (Continued) Driven, -T Torque Value Fasteners Thread Slze Ft -Lb Nm 12 Capscrew, Carrier to Housing 4 50-75 68-102 1/2.1!2.1 13 75-115 102-156 9/16-12 110-165 149-224 518-11 150-230 203-312 314.10 270-400 366-542 M12 x 1.75 74-89 100-120 M16 x 2 181-221 245-300 13 Jamnut, Thrust Screw 3/4-16 150-190 203-258 7/8-14 150-300 203707 1.12-16 150-190 203-258 M22 x 1.5 148-210 200-285 M30 x 1.5 236-295 320-400 14 Nut, Drive Pinion 7/8-20 200-275 271-373 1.0-20 300-400 407-542 1.25-12 700-900 949-1220 1.25-18 700-900 949-1220 1.50.12 600-1100 1085-1491 1.50-18 800-1100 1065-1491 1.75.12 900-1200 1220-1627 M32 x 1.5 738-918 1000-1245 M39 x 1.5 922-1132 1250-1535 M45 x 1.5 996-1232 1350-1670 15 Capscrew, Bearing Cage 3/8-16 30-50 41-68 7/16.14 50-75 68-102 1/2-13 75-115 102-156 9/16-12 110-165 149-224 5/8-11 150-230 203-312 M12 x 1.75 7446 100-130 16 Plug, Oil Filter (Carrier) 3/4-14 25 min. 34 min. 1.5-11.5 120 min. 163 min. M24 x 1.5 5. 47 min. 17 Capscrew, Lack Plate 5/16.18 [---12�a 27-41MIS x 1.25 -26 28-35 Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 N D Series Maintenance Manual Page 2A-1, Driven SPECIFICATIONS DRIVE AXLE ASSEMBLY Manufacturer.................................. .................................................... _........... ............................. ....... Medtor Automotive Wheel Track (Center of Dual Wheels).............................................................................................. 76.62 in. (1946 mm) GearType .............................................. ........... ................................. _.... _........................................................... Hypoid AxleType......................................................................................................................................Pressed Steel Housing RearAxle Lube Capacity ...................................................................._............_............................... 20 Ots. (19.4 liters) CLEARANCE Differential Bearing End Play.......................................................................................................... 0.000 in. (0.000 mm) Differential Gear Run -Out Max.... ................................................................ ..... ............................ 0.008 in. (0.203 mm) Hypoid Gear Backlash (New) ....................................... _..._............................................................ 0.010 in. (0.254 mm) Hypoid Gear Backlash Limits .................................................. ............................ 0.005-0.015 in. (0.127 mm -0.381 mm) Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 pdvarf D Series Maintenance Manual Page 2B2-1 SECTION 2132 TAG AXLE - PIVOTING ARM (D4000 ONLY) CONTENTS OF THIS SECTION SUBJECT PAGE GENERAL DESCRIPTION ............................................. 2132-3 Components .....................................................282-3 MAINTENANCE..................................................... 2B2-4 Inspection.......................................................2B2-4 Alionment .......................................................2132-4 Lubrication......................................................2132-4 SPECIFICATIONS...................................................2B2-5 SERVICE TOOLS....................................................2B2-5 Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PM 03-26-0219 Date Page September 2013 2132.2 D Series Maintenance Manual THIS PAGE INTENTIONALLY LEFT BLANK Driven' Copyright 2013—Motor Coach Industries Infl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 111111111 D Series Maintenance Manual Page 292-3 Driven GENERAL DESCRIPTION The liftable arm tag axle is independently mounted at the rear of the drive axle. The tag axle trunnion arm pivots in two sets of oil lubricated (or grease lubricated) roller bearings inside each of their respective mounts. The pivot action allows tag axle wheels to track while traveling forward or backing. The bearing boxes are bolted to the rear bogie leg mounting plate. 4 n Components Each tag axle assembly has a welded axle arm with machined spindle and trunnion attached, bogie leg bearing box mount, and heavy roller bearing assembly. Tag axle brakes and hubs are attached to complete the assembly. The bearing box mounts are grease filled and sealed by the axle arm at one end, and a flange cover at the other end. The trunnion spindle is machined to accept bearing assemblies, and welded to the axle arm at the other end. The axle arm trunnion and bearings are held in the bearing box mount by a spanner locknut and tongue washer. Figure 1. Tag Axle Assembly 3632 Item Description Item Description Item Description 1 Ring -Wear 9 Washer - Tongue 17 Lockwasher, 1/4 2 Spindle Assembly 10 Cone - Bearing, Inner 18 Cone- Bearing 3 Arm Assembly, Welded 11 Breather - Crenco No. 12758 19 Seal 4 Screw, 1/4-20 x 3/4 12 Fitting - Bushing, 1/4 Male, 1/8 Female 20 Nut - Nylmk, 12-13, Zn PI 5 Plate 13 Box Assembly - Bearing 21 Washer - Flat 12 8 1 0 -Ring 14 1 Shield - Slinger 22 Plug - Magnetic 7 Lodmut 15 1 Screw. 1/4-20 x 3/423 Fitting, 45 Degree Elbow, 3M NPT 8 1 Loo!,Mher 16 1Washer -Flat, 9l32ID Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 282.4 MAINTENANCE Inspection D Series Maintenance Manual Excessive bearing end play could result in premature seal or bearing failure. Periodically inspection of all tag axle arm seals and bearings. (Refer to Section 10 for intervals.) If there is excessive tag axle arm end play, retorque the trunnion bearing locknut as specified. Torque Setting Procedure Seat bearing with locknut and torque nut to 100 ft -Ib (136 Nm). Loosen locknut and retorque to 30 ft -Ib (41 Nm) in steps while rotating the axle arm to seat the rollers. Off Level Check With the axle on a level surface, remove fill plug from hub cap assembly and add lubricant to the hub to the level indicated on the sight glass. Alignment Driver' When installation is completed, align the tag axle arms in accordance with Section 1 - Alignment Pro- cedure. Lubrication Tag axle trunnion bearings are splash fed. Check oil levels periodically. (Refer to Section 10 for inter- vals.) Change the oil when contaminated or when the seals are replaced. Lubricate the tag axle trunnion bearings using lubrication specification S-9 thru S-12 (Multi -Purpose Gear Oil). Copyright 2013 — Motor Coach Industries Int't, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 w D Series Maintenance Manual Page 2B2-5 Driven 2 Figure 2. Bearing Box Assembly Item Description 1 Bearing Box Assembly 2 Arm Assembly 3 Nylock Nut - Torque to 7246 ft -Ib (98-117 Nm) 4 Lube Fitting SPECIFICATIONS TAG AXLE ARM Manufacturer............................................................................................................................................................... MCI Type..................................................... _............... ........................................................................................ Pivoting Arm Camber Angle ......................... ........... ..........__........_......................... _............._.......... ........._....... (.255 positive x.445) Toe -In ............................................ ...... .......... ......... ..................................................... .......... .......... (0.6 in. t .06 in.) BEARING BOX Manufacturer.............................. ..._................................................ _.......................... .................................... ..... ....... MCI Type(Effective with 12758) ................. ..... _.......... _......... ............. _................... _...................................... Grease Lubed SERVICE TOOLS SPANNER WRENCH SOCKET FOR BEARING BOX RETAINER NUT Manufacturer ............. .......................................... _.................................................................. _............................ BAS -13 copyright 2013 — Motor Coach Industries Inn, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Application Approval Form Created by Jesse Mar Fallorin on 03/07/13 Status: Commod Mgr ClOriginator: Fallorin ate: 3ro7113 Cl Engineering:i ate: 3112113 n Comments : ULE W/O Esc CONTROL n Approval #: de: M490678� umber: nT e: - ABSIMCtion Controlate: ct S ec Number Commodity Manager Information : HommMgrName: on Williams Phone: 204) 287-4885 Email : on.williams@mcimach.com Comments : Supplier Information : u Tier Name: ABCO u plier Number: u liar Email. u IierPhone: treat Address : i : tate/Province: Part Information : Number : 00884sot0 art Descri tion : BS WABCO ECU W/O ESC umber: 7.08-5021 escrl Ion : S WASCO ECU W/O ESC rPartart in Number: 7.08.5021 evision :lation Number : 7-14-9530 ct S ec Number Product Spec Revision - MCI Application Information : Used on Coach Models : Ali X D4500 Comm LJ J4500 7-14-9530 Ok D40M Comm ® 04505 ❑ J4500 Conv 7-08-5021 D4005 ❑ D-ISTv ❑ E4500 lication Description List of MCI Drawings and Documents Reviewed : Drawing / Spec Number Revision —:)ascription 7-14-9530 Ok CU INSTL - ABS, D40045, FIXED/STEERABLE TAG 7-08-5021 CU - ABS WABCO W/O ESC MCI Attachments for Supplier : MCI Internal Use Only Attachments tta 07-14-9530_dwg.pdf 07-08-5021_dwg.pdf Supplier Declaration : I affirm that the product described in this document has been approved for the installation and application detailed on this form. Whereas MCI has provided general vehicle application guidelines for the suppliers product, the supplier, as the expert in their product, remains responsible for all aspects of the design integrity, quality and performance of their sub -suppliers component contribution to the product described in this document. Having approved MCI's application of the product and approved the installation, the supplier agrees to warrant their product within the guidelines of the official warranty policy between MCI and the supplier . Supplier Comments: Supplier Request for Equivalent Application Approval Document : u plier Document Number: evision: escr tion : I Engineering prov al: ae: CI Engineering Comments Supplier Attachments: Supplier Approval: Approval History 03/12/13 11:45:57 AM - Jesse Mar Fallorin submitted application to Michael Mi (Mgr App 1). COMMENTS: 03/12/13 11:52:40 AM - Michael Mi forwarded application to CWDemse Borys/OU=WinnipegtO=MotorCoach (Commod Mgr). COMMENTS: 03/12/13 12:37:29 PM - Denise Borys assigned application to Jon Williams COMMENTS: � Application Approval Form `JCreated by Jorge Alarcon on 04/15/13 Status: Originator 1 Originator: orge Alarcon ate: 4/15/13 Cl Engineering: a nce Ramsay ate: 4-31-119,04-31-1119,04-31-1120 ngineeringComments: n Guard system on D model units (GLI) Iication A proval #: 00310 IrCl oriCode: nority1 o ect Number: 490703 licatlonT e: it System- ABS/Traction ControlN #: 7099 -line Date: a/1&2013 Commodity Manager Information : Supplier Information : upplier Name: VVABCO upplier Number: up tier Email: up tier Phone: treat Address: ity: tate/Province: ip or Postal Code Part Information : Part Number : 00 871 251 0, 400 671 800 0, 400 879 zoo 0 upplier Part Description : Guard system Cl Part Number: 4-31-119,04-31-1119,04-31-1120 Iupplier CI Part Description : n Guard system Cl Drawing Number: -31-1121 ravoing Revision : CI Installation Number : 31.1121 Cl Product Spec Number: Product Spec Revision: MCI Application Information : Used on Coach Models: AN D45oo comm LJ J4500 D4000 Comm ® 04505 ❑ J4soo conv D4005 ❑ D-ISTV ❑ E45oo kipplication Description : n Guard System on GLI units List of MCI Drawings and Documents Reviewed : rawin / Spec Number levision Description 31-1118 31-1119 31-1120 31-1121 MCI Attachments for Supplier : MCI Internal Use Only Attachments : Supplier Declaration : affirm that the product described in this document has been approved for the installation and application etailed on this form. Whereas MCI has provided general vehicle application guidelines for the suppliers roduct, the supplier, as the expert in their product, remains responsible for all aspects of the design integrity, quality and performance of their sub -suppliers component contribution to the product described in this �ocument. Having approved MCI's application of the product and approved the installation, the supplier agrees o warrant their product within the guidelines of the official warranty policy between MCI and the supplier. Supplier Comments: Supplier Request for Equivalent Application Approval Document : la lier Document Number vision: scrition: I En ineerin roval te: I Engineering Comments Supplier Attachments : Supplier Approval : Reliability Driven' ATTACHMENT I BRAKE SYSTEM ®Date September 2013 Reliability Driven D Series Maintenance Manual Page 4A-1 SECTION 4A AIR SYSTEM OVERVIEW CONTENTS OF THIS SECTION SUBJECT PAGE GENERAL DESCRIPTION ............................................. 4A-3 Air Supply Components ........................................... 4A-4 Reservoirs and Related Components ................................ 4A-4 Brake Systems ................................................... 4A-5 Brake System Operational Checks ................................... 4A-8 Suspension...................................................... 4A-10 Accessory Air System ............................................. 4A-11 MAINTENANCE..................................................... 4A-11 TROUBLESHOOTING................................................ 4A-14 Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4A-2 D Series Maintenance Manual Reliability Driven- THIS riven THIS PAGE INTENTIONALLY LEFT BLANK Copyright 2013— Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 D Series Maintenance Manual Page 4A-3 GENERAL DESCRIPTION The pressurized air system operates and maintains several vital systems and components such as service, emergency and park brakes, suspension, and entrance door control. Refer to the Air and Electrical Schematics for more information on the interrelation of the air com- ponents. This subsection provides an overview of the air system and related components. Sections 48 to 4F contain detailed information on the operation and main- tenance of the air system and related components. Air system components are discussed under five catego- ries: • Air Dryer/Oil Separator • Brakes/Air Springs • Air Control Components • Air Compressor/Governor • Antilock Brakes System (ABS) I To avoid personal injury when working on or around the air system and its components, the following precautions must be observed: Always chock vehicle wheels. Stop engine when working under a vehicle. Venting vehicle air system pressure may cause vehicle to roll and/or settle. Avoid accessing the suspension components from outside coach wheel well areas. Unintentional actuation of the height control valves with fully Inflated air springs could result in serious injury. Always block the coach body adequately during any inspections and/or repairs in these areas. Vent all air pressure from system before disconnecting component hoses. Never connect or disconnect hoses or lines containing air pressure as they will tend to whip while air escapes. Never remove a component or pipe plug unless you are certain all system pressure has been vented. Never exceed recommended air pressure and always wear safety glasses when working on the air system and components. Never look into air jets or direct them toward anyone. Never attempt to disassemble a component until you have read and understand the recommended procedures. Some suspension components contain powerful springs. Injury can result if not properly disassembled. Use only proper tools and observe all precautions pertaining to use of those tools. Disabling the LOW TAG AIR telltale will void structural warranties. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4A-4 Air Supply Components NOTICE D Series Maintenance Manual One or more of the components described below may not be on specific coach configurations. Refer to the Air and Electrical schematics to verify component list. NOTICE Effective with coach 13051, the Low Air Pressure Switch is located on the Front Accessories Tank on all D models. Air Compressor The air compressor provides compressed air for all air powered components of the coach. Located at the curbside -rear of the coach, the compressor receives air from the intake manifold. The system's pressure is then built up and maintained by the compressor. The com- pressor is driven by and mounted to the engine's front auxiliary drive. Governor The integrated governor, mounted on the air dryer, monitors pressure in the accessory reservoir and loads the compressor when pressure drops to approximately 105 psi (724 kPa). When pressure rises to approxi- mately 125 psi (862 kPa), the governor unloads the compressor and signals the air dryer to purge. Discharge Air Muffler (Ping Tank) The discharge muffler, located in the engine com- partment, receives air from the air compressor dis- charge hose. The muffler removes some of the noise and contaminants from the air prior to its delivery to the air dryer. The muffler has a drain cock and tube for reg- ular draining. Drain daily. Air Dryer The air dryer (located on the front bulkhead in the front axle area) removes water and contaminants from the compressed air prior to delivery to the reservoir tanks. The dryer has two cycles: charge and purge. During the charge cycle, air is cleaned. During the purge cycle, water and contaminants are expelled. The air dryer operates in charge mode when the compres- sor is loaded (compressing air); it operates in purge mode when the compressor is unloaded. Oil Separator Driven The oil separator follows the air dryer in the sys- tem. In high -air -use vehicles, the compressor dis- charge temperatures can allow oil vapor to pass through the dryer. The oil separator removes approxi- mately 95 percent of oil aerosols from the air. Reservoirs and Related Components Supply Reservoir (Wet Tank) The supply reservoir is located to the roadside of center on the rear bulkhead in the front axle area. The auto -draining supply reservoir receives air from the oil separator and supplies air to the remainder of the res- ervoirs. The supply reservoir also supplies air directly to the front -axle kneeling feature. A one-way check valve, located in the supply port of the reservoir, pre- vents backflow, of air to the oil separator. Secondary Brake Reservoir (Front Service) The secondary brake reservoir is located curbside of center on the rear bulkhead in the front axle area. The secondary brake reservoir receives air from the supply reservoir and supplies air to the lower portion of the dual service brake valve. Pressure is protected by a one-way check valve in the supply port. Primary Brake Reservoir (Rear Service) The primary brake reservoir is located roadside of center on the front bulkhead in the drive axle area. The primary brake reservoir receives air from the supply reservoir and supplies air to the upper portion of the dual service brake valve and to the rear relay valve. Pressure is protected by a one-way check valve in the supply port. Park Brake Reservoir (Emergency) The park brake reservoir is located curbside of center on the front bulkhead in the drive axle area. The park brake reservoir receives air from the pressure pro- tection valve in the central heat compartment and sup- plies air to the spring brake valve. Pressure is protect- ed by a one-way check valve in the supply port. Rear Rise Reservoir The rear rise reservoir, located on the engine com- partment floor to the rear of the RH tag axle wheel housing, receives supply air from the air/fuel junction block and delivers control air to the rear rise relay valve. Copyright 2013 - Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Reliability Driven D Series Maintenance Manual Page 4A-5 Accessory Reservoir (Suspension) The accessory reservoir is located on the floor of the front roadside service compartment. The accessory reservoir receives air from the front accessory/suspen- sion air junction block and supplies air to various ac- cessory components either directly or through the front accessory/suspension air junction block and rear ac- cessory/suspension junction block. In -Line Air Filter The in-line air filter, located in one of the delivery ports of the supply reservoir, filters air before delivery to the pressure protection valve. This is a serviceable item and is easily replaced. Pressure Protection Valve The pressure protection valve is located on the right side of the central heat compartment immediately above the central heat core. Access the valve through the central heat door in the front of the #3 baggage bay. The pressure protection valve receives air from the supply reservoir and supplies air to the central heat water valve, park brake reservoir, accessory reservoir, rear accessory/suspension junction block, and front ac- cessory/suspension junction block. Rear Accessory/Suspension Air Junction Block The rear accessory/suspension air junction block is located on the crossmember immediately to the rear of and above the drive axle. This junction block receives air from the pressure protection valve of the park brake reservoir and delivers air to the rear axle suspension leveling valves and to the air/fuel junction block. Air/Fuel Junction Block The air/fuel junction block is located in the engine compartment. This junction block receives air from the rear accessory/suspension junction block and delivers air to components located toward the rear of the coach. Front Accessory/Suspension Air Junction Block The front accessory/suspension air junction block is located centrally in the spare tire compartment im- mediately below the entrance area frame. This junction block receives air from the pressure protection valve in the central heat compartment and delivers air to the front axle suspension leveling valve, accessory air res- ervoir, and air components located toward the front of the coach. Emergency Fill Valves Three emergency fill valves are located at the rear of the front side service compartment. Quick connect valves allow charging the primary, secondary and park reservoirs from an external source. goo Figure 1. Air System Fill Connections Item Description 1 ear Air Connection 2 Front Air Connection 3 Service Brake Connection 4 Whole Coach Air Connection Gladhands Air Couplings Gladhands air couplings (if equipped) are located at the front roadside of the coach, behind the front bumper. Gladhands permit air to the supply reservoir and primary service brakes from an outside source during towing. (Refer to Section 3 - Body for mainte- nance information.) Brake Systems Dual Service Brake Valve The dual service brake valve is located on the rear bulkhead of the spare tire compartment below the driv- er's floor frame. Access this valve using the front bumper release lever, located in the front side service compartment. The primary (upper) portion of dual brake valve receives air from the primary service brake reservoir and supplies air to the following components: • The relay valve control port (rear axle brakes) • The primary stop lamp switch The secondary (lower) portion of the dual brake valve receives air from the secondary service brake reservoir and supplies air to the following components: Copyright 2013 - Motor Coach Industries int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4A-6 D Series Maintenance Manual • The front -axle brake quick -release valve Air Pressure Gauges • The secondary stop -lamp switch • The supply port of the emergency standby valve (see Emergency Brake System) • The relay valve secondary control port (rear axle brakes). The dual brake valve is also connected to the spring brake valve. Relay Valve The relay valve, located on the crossmember im- mediately to the rear and above the drive axle, re- ceives control air pressure from the service brake valve primary portion and supply air from the primary service brake reservoir. The relay valve supplies air to the drive -tag -axle rear service -brake diaphragms. Upon brake pedal release, air exhausts through the exhaust port at the bottom of the relay valve, minimizing brake release time. NOTICE Either control signal from the primary and secondary brake valve delivery ports can actuate (modulate) the relay valve by way of a double check valve integral in the relay valve. Stop Lamp Switches The stop lamp switches (primary and secondary) are located on the rear bulkhead of the spare tire com- partment. These switches close at brake application pressures of 3-5 psi (21-34 kPa) received from the pri- mary or secondary service brake valve delivery ports. This activates the stop lights. Low Air Telltale The low air telltale lamp, located in the left-hand, instrument panel telltale cluster, and the low air buzzer located in the front junction box, activate when the air pressure in the primary or secondary supply reservoirs drops to below 68 +/- 5 psi (469 +/- 34 kPa) and deacti- vate when both these pressures rise above 95 +/- 5 psi (655 +/- 34 kPa). Electrical power for the telltale and butter comes from pressure switches located in the rear supply ports (primary and secondary) of the dual, service -brake application valve. Instrument Panel 4 -int Gauge Driven Figure 2. 4 -in -1 Gauge Two air pressure gauges (front/rear) are located within the 4 -in -1 gauge on the driver instrument panel. The left, lower gauge indicates the air pressure in the front brake system (primary) and the right, lower gauge indicates air pressure in the rear brake system (sec- ondary). Linear Air Pressure Scales Figure 3. Air Pressure Scales 25 PSI Graduations Antilock Brake System (ABS) The antilock brake system (ABS) consists of wheel speed sensors, an electronic controller, modulator valves, an ABS telltale, and diagnostic components. ABS affects the service brake system only. Copyright 2013 - Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 D Series Maintenance Manual Ddven ABS Wheel -Speed Sensors ABS wheel -speed sensors monitor the rotational speeds of the front and drive axle wheels. The sensors send wheel -speed information to the electronic control- ler unit. ABS Electronic Controller Unit (ECU) The ABS electronic controller unit (ECU) receives signals from the wheel sensors and sends control sig- nals to the appropriate air -brake modulator valve(s) to prevent wheel lockup. Front -Axle, ABS, Modulator Valves The front -axle, ABS, modulator valves, located in the front -axle area to the left and right of the front -brake quick -release valve, receive supply air from the quick - release valve and supply air to the front -axle brake chambers. The modulator valves will reduce or hold delivery air pressure to the brake chamber(s) in re- sponse to signals from the electronic controller when the controller determines a pending wheel lockup situa- tion exists. Rear -Axle ABS, Modulator Valves The drive -axle modulator valves, located on the crossmember to the left and right of the rear -axle relay valve, receive air from the rear -brake relay valve and deliver air to the drive and tag axle service brake cham- bers. The modulator valves will release or hold delivery air pressure to the brake chamber(s) in response to signals from the electronic controller when the control- ler determines a pending drive -axle wheel lockup situa- tion exits. ABS Telltale The ABS telltale is located in the right telltale clus- ter. When the ABS is operating normally, the lamp comes on at ignition and then goes out. If there is a fault in the ABS system, the ABS telltale lights. , 1 If an ABS malfunction is Indicated by the ABS telltale lamp, the driver must safely stop the coach and safely check all six wheel ends for an overheat condition. If an overheat condition exists, the coach must NOT be driven until Inspected by a qualified technician. NOTICE Date September 2013 Page 4A-7 In the event of an ABS malfunction, the braking system will default to a normal braking system. Exercise caution to avoid potential wheel -lock conditions. Emergency Brake System If the secondary brake system (front) air pressure is lost, the primary brake system (rear) will continue to function normally. The air gauge will indicate second- ary air pressure loss and the low air buzzer will sound. If the primary brake system (rear) air pressure is lost, the secondary brake system (front) will continue to operate normally. The air gauge will indicate the loss of air pressure in the primary air system and the low air buzzer will sound. The loss of air pressure in the primary reservoir will result in the loss of air pressure in the reservoir port of the spring valve (SR -1). Under this condition and with pressure at the control port from the brake service valve secondary delivery port, the spring valve will ex- haust air pressure going from the delivery port to the control port at the relay parking brake valve. At the same time, the relay valve will exhaust air going to the parking brake compartment emergency port in the drive axle dual brake chambers. The dual chamber power springs will then apply the emergency brakes. As soon as the brake service valve is released, the signal to the spring valve control port will re-establish, and the relay valve will deliver air to the brake chamber emergency port, compressing the power spring and re- leasing the emergency brakes. Park Brake The park brake is used when parking the coach. Pull the push/pull park brake control valve to apply the park brakes. To release the park brakes, push the valve and apply a full service brake application. The push/pull is located to the driver's right. If park reservoir pressure drops below approxi- mately 40 psi (276 kPa), the park brake applies auto- matically. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4A-8 D Series Maintenance Manual Emergency Park Brake Release An emergency park brake release valve is a manu- ally operated on-off control. The valve is spring loaded and remains in the exhaust position unless constant manual force is applied. The emergency park brake re- lease is located on the floor to the operator's left. Brake System Operational Checks NOTICE Coaches are equipped with an emergency park brake air tank that is isolated from the service brake air tanks. The primary and secondary air gauges monitor only the service brake air tanks. In addition to the park brake valve (located In the driver's area), some coaches may also have an emergency park brake release valve. Operational Check for Coaches Without Emer- gency Park Brake Release Valve NOTICE This configuration can be identified by a singular park brake valve used to apply/release the park brake. 1. Apply park brake. 2. Chock both sides of the tires. 3. Using the service brake foot valve, make several applications until the air pressure gauge on the dash reads below 80 psi. 4. Start the coach. Allow the air system pres- sure to reach governor cutout. Turn the igni- tion OFF. 5. Turn ignition to the RUN position, but do not engage the starter. 6. Monitor the pressure gauges on the dash for any air system leakage. Repair any leaks. 7. Push in the parking brake push/pull knob to release the park brakes. The brake calipers on the drive axle willer lease. MC1 8. Apply service brake valve. The brake cali- pers on gill axles will enoace. 9. Exhaust the primary service air tank located just in front of the drive axle. The air pres- sure of the primary gauge in the driver's ar- ea will indicate the loss of air pressure. 10. Apply the service brake valve. The ft= and dtiyg axle brakes will engage. 11. With the primary service air tank still without air pressure, exhaust the secondary air tank mounted behind the front axle. Loss of air brake pressure in the secondary brake tank will be indicated by the secondary air pres- sure gauge in the driver's instrument panel. When the air pressure in the secondary brake system drops below a nominal 45 psi, the park brake valve will = automatically actuate and the brakes on the drive axle will Dot engage. 12. With the primary and secondary service res- ervoirs empty, apply the park brake valve. The brakes on the drive axle will enaace. Release the park brake valve and the drive axle brakes will disengage. This can be re- peated approximately three times until the park brake reservoir located on the right hand side in the drive axle area is below 45 psi air pressure. When the air pressure drops below 45 psi in the park brake reser- voir, the park brake valve will automatically actuate, but the drive axle brakes will not re- lease. 13. Exhaust the park brake tank. The drive axle brakes will remain applied. 14. To check the secondary brake system, start the coach and build up the air pressure to air governor cutout. Turn the ignition OFF. 15. Turn ignition to the RUN position, but do not engage the starter. 16. Release the park brakes. 17. Drain the secondary service reservoir. 18. Apply the service brake valve. The brake calipers on the drive and tag axles will en- gage. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PM 03-26-0219 Date September 2013 D Series Maintenance Manual Page 4A-9 Reliability Dnveri Operational Check for Coaches With Emergen- cy Park Brake Release Valve NOTICE This configuration can be Identified by both a park brake valve and an emergency park brake release valve. The park brake valve Is used to apply/ release the park brake under normal operating conditions. The emergency park brake release valve (clearly labeled) is used in the event there is a sudden loss of air in the service brake air system below 45 psi, which would actuate the park brake system. If the emergency park brake release valve is pressed and held by the driver, the system applies air to the park brake system, allowing the operator to move the coach to the side of the road, if required. 1. Apply park brake. 2. Chock both sides of the tires. 3. Using the service brake foot valve, make several applications until the air pressure gauge on the dash reads below 80 psi. 4. Start the coach. Allow the air system pres- sure to reach governor cutout. Turn the igni- tion OFF. 5. Turn ignition to the RUN position, but do not engage the starter. 6. Monitor the pressure gauges on the dash for any air system leakage. Repair any leaks. 7. Release the park brake. The brakes on the ri axle will release. 8. Apply the service brake. The brakes on all axles will engage. 9. Exhaust the primary service air tank located just in front of the drive axle. The air pres- sure of the primary gauge in the driver's ar- ea will indicate the loss of air pressure. 10. Apply the service brake valve. The fconl and diiya axle brakes will engage. 11. With the primary service air tank still without air pressure, exhaust the secondary air tank mounted behind the front axle. When the air pressure in the brake system drops below a nominal 45 psi, the park brake valve will au- tomaticaily actuate and the brakes on the drilLe axle will engage. 12. With still no air pressure in the primary and secondary air tanks from Step 11, apply and hold down the emergency park brake re- lease valve. The brakes on the dtjyeaxle will release. When the force holding down the emergency park break release valve is re- moved, the air in the system will exhaust, and the d[iye axle brakes will enaaae. NOTICE There should be enough air to allow three park brake overrides before the system Is exhausted. 13. To check the secondary brake system, start the coach and build up the air pressure to air governor cutout. 14. Turn the ignition OFF. Brake Chambers Single -diaphragm MGM service chambers are used on the front and tag axle brakes. MGM spring brakes, which have independent service and spring chambers, are used on the drive axle brakes. Brake Interlock Systems There are three interlock systems employed in the brake system. Two relate to the parking brake release and the other pertains to the drive and tag axle service brake application. Service Brake Interlock: This system requires a 25 psi (172 kPa) application of the service brakes to release the parking brake once the push/pull (PP -1) has been applied. Wheelchair Interlock: The wheelchair lift master switch located on the left side operator panel must be turned off in order to release the parking brakes. Entrance Door Interlock: The entrance door must be closed in order to release the pressure signal to the drive and tag axle relay valve control port (which is applying the service brakes at these axles). Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved- P/N 03-26-0219 Date September 2013 Page 4A-10 Suspension D Series Maintenance Manual The suspension system automatically maintains ride height using leveling valves, air springs, and vari- ous suspension components. Leveling valves adjust air spring pressure. A pressure protection valve prevents over pressurizing the air springs. Tag axle air springs also have manual control valves. NOTICE Refer to Section 12 for suspension system maintenance Information. Air Springs Air springs used at each axle optimize load -carry- ing capacity and ride quality. Leveling Valves One leveling valve is located at the center of the front axle and two are located on either side of the drive axle suspension. These valves receive air pres- sure from the suspensionlaccessory air blocks, re- sponding to maintain air -spring ride -height at the front and drive axles. The front leveling valve controls only ride height, while the drive axle leveling valves control both ride height and side-to-side leveling. The tag axle air springs receive air pressure from the drive axle leveling valves to provide a roughly two to one load sharing on the drive and tag axles. The lev- eling valves are damped to respond to changes in stat- ic load (payload) but to not respond to dynamic chang- es (road irregularities) and so consume little or no air over the road. Rear Rise The rear rise feature prevents rear bumper scuffing in off-highway situations by increasing air pressure to the drive and tag axle air springs. This raises the rear bumper approximately 3 in. (76 mm) above normal ride height. The control valves are mounted on the rear rise air tank in the engine compartment near the RH wheel housing. Check valves and a relay valve are mounted above the drive axle. The rear rise switch is on the op- erator's switch panel. When the coach is in rise mode, a telltale lights and an alarm sounds. Kneeling The kneeling control, located in the front of the #1 roadside baggage compartment, optimizes kneel and recovery air pressures to the front axle air springs and Niven controls a remote mounted relay valve to minimize kneel and recovery times. Air is supplied from the sup- ply reservoir. The kneeling feature is activated by a switch on the driver's console. When the coach is in the rise mode, a telltale lights and an alarm sounds. Tag Axle Unload Tag axle unloading valves, located in the engine compartment forward of the curbside rear service door, provide for short term unloading of the tag axle air sus- pension for tire changing or hoisting. A pressure switch downstream of the unloading valves senses the low air when the tag axle is unloaded and activates the low tag air telltale in the driver's area. NOTICE Driving with the tag axle unloaded can result in structural damage to the coach. Disabling the LOW TAG AIR telltale voids structural warranties. Double Check Valves Double check valves are used where it is neces- sary to supply air from, or exhaust air to, two different components used to control a third component. They have two supply ports and one delivery port and, under normal conditions, when one supply port is open to the delivery port, the other supply port is closed. Location and function of double check valves is as follows: On the delivery port of the front axle lev- eling valve to control air pressure in the front axle suspension bellows using air supplied either from (or exhausted by) the leveling valve to maintain ride height or, to provide for quick recovery from or quick kneeling during a kneeling cycle using air supplied from (or exhausted by) the kneeling feature relay valve. On the delivery line of the drive axle lev- eling valves to control air pressure in the rear axle suspension bellows using air supplied either from (or exhausted by) the leveling valves to maintain ride height or, to provide for quick rising or quick recovery during a high-rise cycle using air supplied from (or exhausted by) the rear high-rise feature relay valve. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 D Series Maintenance Manual Page 4A-11 Tag Axle Caster Control Valve The self -steering tag axle solenoid control valve automatically operates the air cylinders of the latching and locking mechanism of the castering system in con- junction with the speed switch. The tag axle caster con- trol valve is mounted to the right of the rear junction box. Accessory Air System Hot Water Valve An electrically -controlled, air -actuated, on-off type hot water valve is used on this coach. The main valve is mounted adjacent to the pressure protection valve in the central heat compartment. Air Cylinders Various air cylinder actuators are fitted throughout the coach, such as the entrance door lock overrule valve and the wheelchair lift sliding door overrule valve. The bi-part door is air -actuated and the wheelchair passenger door is air -assist. MAINTENANCE Maintenance procedures for specific components can be found in Sections 4B -41F and in other sections in this manual. Follow the maintenance intervals speci- fied in these sections or those given in the Preventive Maintenance Schedule for the air system in Section ID, I To avoid personal injury when working on or around the air system and Its components, the following precautions must be observed. Always block the vehicle wheels. Stop engine when working under a vehicle. Venting vehicle air system pressure may cause the vehicle to roll or settle. Avoid accessing the suspension components from outside coach wheel well areas. Unintentional actuation of the height control valves with fully inflated air springs could result in serious injury. Always block the coach body adequately during inspections or repairs in these areas. Vent all air pressure from the system before disconnecting component hoses. Never connect or disconnect hoses or lines containing air pressure as they can whip when air escapes. Never remove a component or pipe plug unless you are certain that system pressure has been vented. Never exceed recommended air pressure and always wear safety glasses when working on the air system and components. Never look Into air jets or direct them toward anyone. Never remove, install, or disassemble a component until you have read and understood the recommended procedures. Some components contain powerful springs and injury can result if not properly handled. Use only correct tools and observe all precautions pertaining to use of those tools. Disabling the LOW TAG AIR telltale voids structural warranties. Brake linings contain non -asbestos fibers that may be harmful. Read the cautions pertaining to servicing brake linings before beginning work. Service Intervals If component part does not pass the service in- spection/check, perform the required preventive main- tenance as prescribed per service literature. Warranty Policy Preventive maintenance or component servicing is not warrantable. Haldex warranty will be void if preven- tive maintenance is not conducted. I When working on air system components the following precautions should be observed. 1. Stop the engine when working under a vehicle. Always block the vehicle wheels to prevent a fore or aft roll. Bleeding off system pressure may cause the vehicle to roll. Keep hands away from brake chamber push rods and brake adjusters; they may apply as system pressure drops. 2. Never connect or disconnect a hose or line containing air pressure. It may whip as air escapes. Never remove a component or a pipe plug unless you are certain all system air pressure has been exhausted. Copyright 2013 — Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4A-12 D Series Maintenance Manual 3. Never exceed recommended working air pressure and always wear safety glasses when working with pressurized air. Never look directly into component ports or direct a pressurized air flow at anyone. 4. Never attempt to disassemble a component until you have read and understood all recommended procedures. Some components contain powerful springs and injury can result It not properly disassembled. Use only proper tools and observe all precautions pertaining to the use of those tools. Air Compressors For detailed information on the air compressor, re- fer to the appropriate section in this manual. NOTICE Applications may vary, consult your engine manufacturer's service manuals for specifics. Check Compressor Build -Up Time: a. With the engine shut off, open the air tank drain valve (wet, primary and secondary) and allow all of the air pressure to escape prior to closing the valve. NOTICE If the vehicle air gauges are not easily read (5 psi increments), install a pressure gauge In the wet tank or In the governor line to the wet tank. b. Start the engine and run it at maxi- mum governed speed - c. Using a stop watch, record the pres- sure build-up time from 85 to 100 psi. If necessary, repeat the test several times to verify the accuracy of the re- sults. 1. 25 seconds or less no service is required. 2. 26 seconds or more require un - loader servicing. NOTICE Driven The best way to evaluate a compressor's performance is to compare today's build-up time to what it was originally. ff the build-up time has Increased more than 30 percent, service the unloaders. For example, If original buildup time was 10 seconds, then today's was at 13 seconds, service the unloaders. d. If build-up time remains slow after servicing the unloaders, check for blocked or restricted discharge line, air dryer or inlet air filter (if used). 2. Compressor Air Filter Inspection: a. Hold a strong light next to the air fil- ter. If the light passes through the fil- ter, consider it suitable. It any dark spots are noticed, replace the filter. Haldex does not recommend clean- ing the filter with compressed air or solvents. NOTICE When checking unloader operations, it will be necessary to purchase a new unloader gasket for that particular model of compressor. Brake Actuators Actuators Mounting Nut Torques Stud Size Torque Torque Found On Ft -Lb Nm 7/16-14 40-59 54-67 T-9, T-12, T-16 1/2-13 60-75 81-101 T-16 Tl 6, T-20, T-24, T-30, 5/8-11 100-145 136-197 T-36, Maxi -I, Maxi -R -Series HRPT, Nombre, 5/8-18 100-145 136-197 N34000, N360DO 3/4-16 110-150 149-203 T-50 Non -U.S. M16 x 1.5 100-155 136-210 Applications Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 SII D Series Maintenance Manual Page 4A-13 Driverf NOTICE All tests should be done with the engine off, wheels blocked and at full system pressure (120 psi). If the vehicle air pressure decreases rapidly during this Inspection, we recommend the use of shop air to maintain vehicle air pressure only. 2. Air Leakage Test (Parking/Emergency Brakes Released) a. Have the driver release the parking brake and emergency brakes. b. With a stethoscope, listen to each spring brake actuator for the sound of air leakage. If needed, apply liquid soap to all air line connections and at the seam between actuator housing and the diaphragm cover. NOTICE If the vehicle fails this test, it should be immediately placed in "Dead Line Status". 5. Parking Brake a. With the parking brake applied, start the engine. b. Apply the service brakes and place the vehicle in drive. C. Slowly release the service brakes. If the vehicle starts moving, the vehicle has failed the test. Immediately place the vehicle in "Dead Line Status". Dc not exceed idle speed. Air Dryers NOTICE NOTICE Minor air leaks in the seam area around the To perform the test properly, completely drain the diaphragm may be corrected by tightening the wet tank prior to a day in service. Allow the vehicle assembly clamp band. to complete It's normal daily route. At the end of 3. Air Leakage Test (Brakes Applied) the day, perform the performance inspection test a. With parking brake released, have outlined below. the driver make a hard drive appli- 1. Air Dryer Performance Inspection: cation. a. With a container under the wet tank b. With a stethoscope, listen to each drain valve (petcock), open the drain brake actuator and service chamber valve and collect the moisture that for the sound of air leakage. If need- has accumulated in the wet tank, ed, apply liquid soap to all air line (for the one day of service). connections and at the seam be- b. Measure the amount of moisture in tween actuator housing and the dia- the container: phragm cover. 2 ounces or under - 4. Parking Brake/Emergency Brake Test (Air) ctio cates the dryer is tunction- a. Have the driver release and apply ing properly. the parking brake/emergency 3 ounces or more - Verify brakes several times. the purge time is greater b. Look at the brake adjuster as the than 17 seconds. If so, parking brake valve is being applied replace the coalescent filter and released. Every time you hear and desiccant canister. the exhaust of air, the brake adjust- ers should move and apply the park- NOTICE ing brake/emergency brake. Dryer purge time Is the time in seconds that it takes to drop the purge volume pressure from 120 psi to 5 psi. Copyright 2013 - Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4A-14 D Series Maintenance Manual ReliobihN orlverf TROUBLESHOOTING Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Condition Possible Cause 1 Air pressure drops quickly with engine stopped and brakes released. Leaking brake vakre tubing or hose line. Leaking elsewhere in the air brake system. 2 Air pressure does not rise to normal. Defective air gauge (registering incorrectly). Excessive leakage. Reservoir drain cock open. Governor out of adjustment or defective. Defective compressor. 3 Air pressure rises to normal too slowly. Excessive leakage. Clogged air cleaner. Engine speed too low. Worn compressor. Excessive carbon in compressor cylinder head or discharge line. 4 Air pressure rises above normal. Defective air gauge (registering incorrectly). Governor out of adjustment or defective. Unloading valve cavities or unloading passage in compressor cylinder head blocked with carbon. Compressor unloading valves stuck closed. 5 System pressure not maintained. Restriction in compressor inlet or discharge lines or cavities. Leaking or broken discharge valves. Inlet valves worn excessively or stuck open. -Excessive system leakage. Excessive wear on piston rings and/or cylinders. 6 Noisy compressor operation. Excessively worn drive coupling. Worn or burned out bearings. Excessive wear (improper lubrication to the compressor). Restrictions in the cylinder head or discharge line. 7 Compressor passes excessive oil. Oil supply lines to compressor or return lines hooded. Back pressure from engine crankcase. Excessive engine oil pressure. Defective oil seal or oil seal ring in end cover. Piston rings improperly installed. Excessive ring or cylinder wear. 8 Compressor knocks continuously or intermittently. Loose drive coupling. Worn or burnt out bearings. Excessive carbon deposits in compressor cylinder head. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 W D Series Maintenance Manual Page 4A-15 Driven - TROUBLESHOOTING (CONTINUED) Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Condition Possible Cause 9 Compressor fails to unload. Defective or worn unloader pistons or bores. Inlet cavity restrictions. Defective governor. Cavity beneath the unloader pistons restricted. Unloader mechanism binding. 10 Dryer is constantly cycling or purging. Excessive system leakage. Defective check valve between air dryer and wet reservoir or at air dryer outlet. Defective governs. Leakage at purge valve in air dryer end cover (control side). Compressor unloader mechanism leaking excessively. 11 Water in air system reservoirs. Desiccant requires replacement leakage (see Condition #10). Air system was charged from outside air source, bypassing dryer. Air dryer not purging (see Condition #15). Purge (air exhaust) time insufficient due to excessive system. 12 Air dryer safety valve popping off or exhausting air. Desiccant cartridge plugged or saturated Defective check valve, fittings, hose, or tubing between air dryer and supply reservoir. Safety valve out of adjustment. Air pressure in the air brake system above normal. Frozen or blocked air line. 13 Constant exhaust of air at air dryer purge valve exhaust or unable to build system. Air dryer purge valve leaking excessively pressure. Air dryer purge valve leaking excessively pressure. Defective governor. Purge valve frozen open, faulty heater or thermostat, faulty wiring, blown fuse. Inlet and outlet connections reversed Defective check valve between air dryer and wet reservoir. Kinked or blocked (plugged) discharge line. Excessive system leakage. 14 Air dryer does not purge or exhaust air. Broken, kinked, frozen, plugged, or disconnected purge control line. Faulty air dryer purge valve. 15 Desiccant material being expelled from air dryer purge valve exhaust (may look like whitish liquid, paste, or small beads). This condition is almost always accompanied by one or more of the Conditions 11-16; see related causes for these condition above. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4A-16 D Series Maintenance Manual Reliobility, Driven TROUBLESHOOTING (CONTINUED) Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Condition Possible Cause Defective cloth covered perforated plate in air dryer desiccant cartridge or improperly rebuilt desiccant cartridge. 16 Unsatisfactory desiccant life. Compressor passing excessive oil. Faulty heater and thermostat, wiring, fuse not allowing purge (cold weather operation only). Excessive system pressure built up within air dryer, caused by either plugged desiccant, check valve failure. 17 Air dryer end cover separates from air frozen or obstructed discharge line (between air dryer and dryer housing during operation. wet reservoir) or governor failure in conjunction with safety valve failure. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 D Series Maintenance Manual Page 46-1 SECTION 413 AIR DRYER - WABCO CONTENTS OF THIS SECTION SUBJECT PAGE GENERAL DESCRIPTION ............................................. 4B-3 Components..................................... .............4B-3 Operation.......................................................4B-4 MAINTENANCE.....................................................4B-4 Inspection.......................................................4B-4 Desiccant Cartridge Replacement ................................... 4B-6 AIR DRYER TROUBLESHOOTING ..................................... 4B-7 SPECIFICATIONS ...................................................48.9 Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page as -2 D Series Maintenance Manual Reliability DO"rf THIS PAGE INTENTIONALLY LEFT BLANK Copyright 2013 — Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. PM 03-26-0219 W D Series Maintenance Manual Driven GENERAL DESCRIPTION The coach may be equipped with the Meritor Web - co System Saver 1200 Plus single cartridge air dryer with integrated governor. It includes a pressure relief safety valve, replaceable coalescing spin -on cartridge, built-in heater, and a muffler for noise suppression.The spin -on cartridge allows for simplified maintenance and requires less than 5 minutes to replace. Components System Saver Air Dryer 45295 Figure 1. Wabco System Saver Air Dryer Item Description 1 Desiccant Cartridge 2 Air Dryer Supply Hose 3 Airline to Reservoir Assembly 4 Heater Electrical Connection 5 Muffler 6 Air Dryer Assembly Date September 2013 Page 4B3 The air dryer includes a desiccant cartridge, heat- er, outlet check valve, pressure relief valve, purge valve, turbo cut-off valve, heater power harness, and a purge silencer (muffler). • Desiccant Cartridge: A cylindrical steel housing containing the filter elements and desiccant needed to filter and dry system air. Spin-on/spin-oft design allows quick and easy maintenance. • Heater: Located in the air dryer base, the heater prevents water that collects in the air dryer from freezing. It consists of a cylindri- cal resistive -type heating element and a small circular thermostat. • Outlet Check Valve: A valve located in the outlet port (port 21) of the air dryer. It pre- vents air from flowing back through the air dryer and escaping out the purge valve during a compressor unload cycle. • Pressure Relief Valve: An attached valve that protects the air dryer from over -pres- surization. • Purge Valve: A valve located on the bottom of the air dryer base that remains open during a compressor unload cycle. It allows collected moisture, condensation, and con- tamination to be expelled from the air dryer during a purge cycle. • Turbo Cut-off Valve: A valve located in the inlet port of the air dryer. It closes the path between the air compressor and the air dryer purge valve during compressor unload. This prevents a loss of turbo- charger boost pressure during a compres- sor unload cycle, thereby maintaining boost pressure for maximum engine horsepower. • Heater Power Harness: Twelve -inch cable with Metri-Pack plug provides electrical connection to air dryer heating unit. • Purge Silencer (Muffler): Used to reduce the noise level of an air dryer purge. Copyright 2013— Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 413-4 D Series Maintenance Manual ReliabityDlver Operation MAINTENANCE During system pressure build-up, compressed air Inspection passes into the air dryer where the filter system re- moves contaminants and passes the air into the drying Periodically inspect the air dryer (refer to Section stage. 10 for intervals): Moisture -laden air passes through the desiccant bed in the air dryer cartridge and moisture is retained by the desiccant. Moisture that condenses out also col- lects in the base of the dryer. When the compressor unloads, the water is expelled and dried air flows back through the dryer, drying the desiccant for the next cy- cle. Air Dryer Cycle 1. The governor turns the compressor on when supply tank pressure drops below cut- in pressure, between 100 psi and 110 psi (689-758 kPa) depending on governor settings. 2. Compressed air passes into the air dryer at the inlet port. • Moisture -laden air and contami- nants pass through the desiccant. • Moisture is retained by the desic- cant and also collects in the base of the dryer. • Contaminants are removed as air passes through the desiccant bed. 3. The governor turns the compressor off when system reaches cut-out pressure, between 120 psi and 130 psi (827-896 kPa) depend- ing on governor settings. 4. When the compressor unloads, the purge valve opens: • Dry air flows from the integrated purge tank back through the air dryer. Air can be felt and heard flow- ing from the purge valve for an extended period of time. • Dry system air flows back through the air dryer to regenerate the des- iccant. 10 psi (69 kPa) is taken from the supply and secondary tanks for the regeneration. 1. Check for moisture in the air system by opening reservoirs, drain cocks, and drain valves. If water is present, the desiccant cartridge may require replacement, but first verity that one of the following conditions is not at fault: a. An outside air source that bypassed the drying bed has been used to charge the system. b. Air usage is exceptionally high due to accessory air demands or an unusu- al requirement that does not allow the compressor to load and unload normally. Check for high air system leakage. C. The vehicle has been operated in a climate where the daily temperature range exceeds 30°, resulting in water condensing in the air brake system. NOTICE During inspection for water, a small amount o/ oil may be detected. This should not be considered a reason to replace the desiccant. 2. Check the mounting bolts for tightness. Torque to 22-30 ft -Ib (30-40 Nm) if neces- sary. 3. Perform the Heater Resistance, Leak, and Operation Tests described below. Copyright 2013 - Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 N D Series Maintenance Manual Page 4B-5 Driven Heater Resistance Test Repair Leaking Connections To avoid damaging components, Meritor WABCO recommends performing this resistance check with the heater in place. NOTICE NOTE., The dryer temperature must be in thermostat closed range (below 45°F) In order to check heater resistance. 1. Set volt -ohmmeter to ohms. 2. Disconnect vehicle harness at the heater. 3. Remove the two screws holding the heater body in place. 4. With wires connected and correctly secured, touch one probe to each heater element lead. 5. Measure the resistance. Acceptable resis- tance is 5.0-7.0 ohms for the 24 Volt unit. 6. If resistance is less than 5.0 ohms, replace the heater. 7. Reinstall components and vehicle harness. Leak Test 1. Drain air from all system tanks. 2. Close reservoir draincocks. 3. Start the vehicle. Allow air system pressure to build while engine idles. 4. When the system reaches cut-out pressure there will be a purge, or strong blast of air, followed by a mild flow which will last 10-25 seconds. 5. Shut off the engine. 6. Apply a soap solution to each connection that contains pressurized air. Check the connections to see if soap solution bubbles. 7. It no soap bubbles appear, the connections are sealed properly. 8. If soap bubbles do appear, the connections are NOT sealed properly. 1. Drain all reservoirs. 2. Remove leaking connection. 3. Inspect the connectors and ports for dam- aged threads or cracks. Replace if neces- sary. 4. Apply pipe sealant to the connection. 5. Repeat leak test until all connections are sealed. Operation Test 1. Check compressor loaded and unloaded cycle. When the compressor is in the loaded cycle, air pressure will build to approximately 120 psi (827 kPa) (cut-out pressure). When the compressor reaches the unloaded cycle, the air dryer will purge, initiating regeneration of the air dryer. 2. During the regeneration cycle, which lasts from 10-25 seconds on regeneration style air dryers, the supply and secondary tanks will drop approximately 10 psi (69 kPa) in pressure. Check the secondary air gauge on the vehicle dash panel to verify this drop. NOTICE A 10 psi (69 kPa) drop /n pressure in the secondary air system is normal for Meritor WABCO System Saver Series regeneration style air dryers. On purge -tank style air dryers, the regeneration cycle time is dependent on the size of the tank. There should be no visible pressure drop during regeneration. if there Is a visible pressure drop, perform a check valve leak test on the system check valves. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. WN 03-26-0219 Date September 2013 Page 4B-6 D Series Maintenance Manual Desiccant Cartridge Replacement Air Dryer Removal I To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury can result. Remove all air from the air system before you service any air system component. Pressurized air can cause serious personal injury. 1. A replacement kit contains one cartridge and one O-ring. 2. Loosen and remove the old cartridge. Use a strap wrench if necessary. NOTICE NOTE: H seats do not ensure a tight seal, replace the air dryer. 3. Remove and discard O-ring from dryer base. 4. Inspect and clean seal seats. Repair any mi- nor damage. 5. Lubricate and install the new O-ring on stem. 6. Thread the replacement cartridge onto the air dryer base until the seal touches the base. Tighten the cartridge clockwise one additional turn. Do not overtighten. Driverf 1. Drain all pressure from the air system. Disconnect all air lines. Use markers to label the lines for proper reinstallation. 2. Disconnect the heater electrical plug from the heater receptacle. 3. Remove the three mounting bolts. Remove the air dryer from its mounting location. Air Dryer Installation 1. Attach the new unit to the frame or mounting bracket with new mounting capscrews and washers. 2. Torque mounting bolts to 22-30 ft -Ib (30-40 Nm). 3. Connect heater electrical plug to heater re- ceptacle. 4. Reconnect all system air lines. 5. Test the installation for correct operation. Refer to the procedure in this section. Integrated Governor Replacement 1. Remove the two mounting bolts, governor and gasket. Discard the gasket. 2. Install the governor and a new gasket in po- sition on the air dryer. 3. Install the mounting bolts and tighten to 14.75 ft -Ib (20 Nm). Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4s-8 D Series Maintenance Manual Reliability Driven AIR DRYER TROUBLESHOOTING (Continued) Condition Possible Cause solution Air dryer purges too often, Leak m line between supply tank and Repair air line. perhaps as frequently as governor. Leaks in the air system., Repair leaks. every 15 seconds, accompanied by excessive cycling of the compressor. Excessive air system demands. Increase air system capacity or reduce air demand. Outlet check valve not seating. Inspect and replace outlet check valve as needed. Air governor has less than 16 psi (110 kPa) Replace air governor. range. Leaking air compressor unloader(s). Inspect compressor. Repair/replace per manufacturers instructions. Air flows out of purge valve Turbo cut-off valve not sealing. Replace turbo cut-off valve. Outlet check valve not seating. Replace outlet check valve. entire time compressor is unloaded. Rapid -spitting" of air from purge valve in small Compressor not completely unloading when cutout pressure is reached, Inspect compressor. Repair/replace per manufacturer's instructions. amounts. Frequency varies with engine speed. Air leak at turbo cut-off valve vent. Rubber seal damaged or missing. Temperature of air coming into dryer is too high — not enough cooling takes place before dryer inlet. Move dryer farther from compressor. Add additional compressor discharge line before air dryer. Add cooling coil or heat exchanger before air dryer. NOTE: Inlet air temperature must not exceed 175°F (80°C). Valve bore worn excessively. Inspect valve bore for wear. if a new turbo cut-off valve does not seal in a clean, lubricated bore, replace the air dryer. Piston is broken. Replace the turbo cut-off valve. Air dryer frozen (water collecting in base of dryer is freezing). No electrical power to heater connector. Check for a blown fuse. Repair heater circuit. NOTE: There must be power to the heater connector the entire time the vehicle's ignition is ON. Low voltage to healer connector. Repair cause of low voltage, such as poor electrical ground, bad connections, corroded wire splices, etc. Heater assembly not working. Replace heater assembly. Wrong voltage air dryer used; i.e., 12 -volt Replace with correct voltage air dryer. air dryer used in a 24 -volt system. Copyright 2013 - Motor Coach Industries Int'I, Inc. and Its subsidiaries. All Rights Reserved. P/N 03-26-0219 0 D Series Maintenance Manual Driven' AIR DRYER TROUBLESHOOTING (Continued) Date September 2013 Page 4B-9 Condition Possible Cause Solution No air pressure build-up in system. Air dryer not plumbed correctly (connections reversed). Ensure compressor discharge line is plumbed to air dryer port 1, and air dryer port 21 is connected to vehicle's supply tank. Wrong air line connected to dryer port 4. Ensure dryer port 4line is connected to the "UNU port of the air governor. Air governor not working properly. Inspect governor per manufacturers instructions. Repair or replace as needed. Air system leaks, such as compressor Locate leaks) and repair. discharge line, air dryer, reservoirs, brake or suspension valves, etc. Air dryer leaks from purge valve. Refer to purge valve condRions listed in this chart. Water, oil, or sludge in air system tanks. Desiccant contaminated with oil. Replace desiccant. Inspect compressor per manufacturer's instructions. Water in system tanks. Desiccant saturated. Maintenance interval not followed. Replace desiccant cartridge. SPECIFICATIONS AIR DRYER Manufacturer..... Type.................. ...Meritor WABCO n Saver 1200 Plus Copyright 2013 — Motor Coach Industries Ind, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 413-10 D Series Maintenance Manual aeliobility Driven THIS PAGE INTENTIONALLY LEFT BLANK Copyright 2013 — Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 DFivarf D Series Maintenance Manual Page 4C-1 SECTION 4C BRAKES, DISC - EX225 CONTENTS OF THIS SECTION SUBJECT PAGE General Description...............................................4C-3 Components.....................................................4C-7 Operation.......................................................4C-8 MAINTENANCE.....................................................4C-12 Inspection.......................................................4C-13 Caliper Assembly ................................................ .4C-21 BrakePads......................................................4C-23 PistonBoots.....................................................4C-29 Caliper Bridge....................................................4C-30 TESTING...........................................................4C-34 TROUBLESHOOTING................................................ 4C-38 TORQUE CHART .................................................... 4C-40 Copyright 2013 — Motor Coach Industries Infl, Inc. and its subsidiaries. All Rights Reserved. PSN 03-26-0219 Date September 2013 Page 4C-2 D Series Maintenance Manual Reliability Driven THIS PAGE INTENTIONALLY LEFT BLANK Copyright 2013— Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PSN 03-26-0219 Date September 2013 111 D Series Maintenance Manual Page 4c-3 IMlobYtly Ddverr GENERAL DESCRIPTION The EX225 air -actuated disc brakes are basic equipment on the front, drive, and tag axles. The brake can be installed on any axle can be used for vehicle parking when equipped with a service spring brake chamber. The basic operation of the caliper is simple, but it is important that the features of the load insensitive auto- matic adjuster are fully understood. It is essential that the correct service procedures be observed to ensure that the brake gives satisfactory service throughout its working life. Figure 1. Hub and Rotor, EX225 Disc Brakes with Unitized Wheel Ends and Pro -Torp® Nut For Front Axles (Assembly) Item Description 1 Hub Assembly (With Studs, Nuts, and Plug) 2 Stud - Wheel 3 Plug - End Play Port 4 Wheel Nut 5 Rotor 6 Bearing Assembly - Complete with Tone Ring 7 Kit, Fasteners, UWE HUB (12 pcs. Capscrew and Washer)` 8 Washer, Hardened 9 Nut - Pro -Torg 3-12 in. Hex with Keeper 10 Keeper - Pro-Torq Nut Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4c-4 D Series Maintenance Manual Reliability Driverf IMA Figure 2. Hub and Rotor, EX225 Disc Brakes With Preset® Hubs For Drive Axles (Assembly) Item Description 1 Hub and Rotor With Bearings, pacer, Seal, and rods (Assembly) 2 Hub and Rotor (Assembly) 3 Hub Assembly With Bearings, Spacer, Seal, and Studs 4 Rotor, EX 225 Disc Brake 5 Kit - Rebuild, Preset, With Bearings, Spacer, and Seal 8 Seal - Drive Axle, Preset, Oil 7 Kit - Fasteners, Drive Axle, Preset, (10 pcs. Capscrews and Washers) 8 Nut - Pro -Torg, 4.3/8 in., octagonal With Keeper 9 Keeper - Pro-Torq, Nut 10 Tool - Socket, 4.3/8 in., Octagonal (Not Shown) 11 Wheel Stud - Alum/Steel Wheel 12 Wheel Stud - Steel Wheel 13 Wheel Nut Not Shown Tone Ring Copyright 2013 - Motor Coach Industries Int'), Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 IYM11111111 D Series Maintenance Manual Page 4c-5 Reliability Drlveri 43906 Figure 3. Hub and Rotor, EX225 Disc Brakes with Unitized Wheel Ends and Pro-Torq@ Nut For Tag Axles (Assembly) Item Description 1 Hub Assembly (With Studs, Nuts, and lug) 2 Stud - Wheel 3 Plug - End Play Port 4 Wheel Nut 5 Rotor 6 Bearing Assembly - Complete with Tone Ring 7 Kit, Fasteners, UWE HUB (12 pos. Capscrew and Washer) 8 Washer, Hardened 9 Nut - Pro-Torq 3-1/2 in. Hex with Keeper 10 Keeper- Pro -Torg Nut Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. Ail Rights Reserved. PIN 03-26-0219 Date September 2013 Page 4C-6 D Series Maintenance Manual Reliability Driven Im •n r• 10714 Figure 4. Hub and Rotor, EX225 Disc Brakes With Preset® Hubs For Tag Axles (Assembly) Item Description 1 Capscrew 2 Hubcap 3 Pro-Torq Spindle Nut 4 Rotor -to -Hub Capscrew 5 Wheel Stud 6 Pre Set. Hub 7 Rotor 8 EX225 Disc Brake 9 Torque Plate -to -Spindle Capscrew 10 Torque Plate -to -Caliper Capscrew 11 Torque Plate 12 Spindle Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved PIN 03-26-0219 Date September 2013 W D Series Maintenance Manual Page 4C-7 ortVen Components The Meritor EX225 Air Disc Brake assembly con- tains several major components. These components and other related parts will be discussed below and in the MAINTENANCE portion of this section. Lining Assemblies The brake linings (pads) are the components most likely to require servicing. Two bonded lining assem- blies are required for each brake caliper. The brake lin- ing assemblies are located on the inner and outer rotor surfaces and supported by the carrier. Torque Plate The torque plate holds the carrier in position at all times and is the only brake component rigidly attached to the axle. The torque plate provides mounting holes for carrier and axle attaching bolts. Carrier The carrier is a heavy casting that straddles the ro- tor. It is mounted rigidly to the axle via the torque plate. The carrier locates the caliper via the caliper slide pins, which are fully enclosed. The carrier also provides the abutment surfaces for the brake lining assemblies, which transfer the braking load directly to the axle, rather than through the caliper slide pins. The slide pins guide only the squeezing ac- tion of the caliper. 43312 Figure 5. Dust Shield Item Description 1 Screw 2 Blue Loctite Adhesive 3 Washer 4 Dust Shield All brakes are fitted with dust shields. Shown is an example of a common dust shield installation. All dust shields install in a similar way. Apply Loctite to threads and torque to 20-25 ft -Ib (27-34 Nm). Caliper The disc brake caliper houses the internal actuat- ing components and the caliper mechanism. The cali- per maintains the correct brake shoe contact with the rotor. The caliper rides on two slide pin assemblies. Air Chamber The EX225 air -actuated disc brake has a direct - mounted air chamber attached to the caliper housing. The air chamber operates directly onto the internal op- erating shaft assembly. NOTICE Replace both LHRH air chambers (on any axle) at the same time. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-8 Hub and Rotor Assembly D Series Maintenance Manual The disc brake rotor is bolted to a machined flange on the wheel hub. The vented rotors are designed to al- low the brake shoe linings to ride against the inner and outer surfaces while being actuated. 11_'01 Figure 6. DiscPlus EX225 Air Disc Brake Item Description 1 Rota 2 Caliper Housing Assembly 3 Air Chamber 4 Bridge 5 Carrier 6 Hub Assembly Operation The air chamber is attached to the caliper housing and operates directly onto the internal operating shaft assembly. As the pads wear, adjustment takes place automatically and independently of the load. Load in- dependent means adjustment takes place under very small clamping forces, preventing over adjustment and minimizing air consumption. The force introduced from the air chamber is ampli- tied by the geometry of the operating shaft. The clamp- ing force is transferred to the inboard pad through the halt -bearings, rollers, tappets, pistons and pistons heads. Once the inboard pad is applied, the force of re- action through the floating caliper housing assembly Driven and bridge pulls the outboard pad against the brake ro- tor. The forces created by the friction of the brake pads on the brake rotor are transferred at the ends of the pads onto the carrier, which is rigidly mounted to the axle. The brakes are released by reducing the input force on the operating shaft, thus reducing the clamp force of the brake. The return spring then returns the clamping mechanism and the operating shaft back to their starting position, leaving the pads with a defined running clearance to the rotor. The small runout of the brake rotor and hub -bearing clearances will then gen- erate a small clearance for the outboard pad through only a few revolutions of the rotor. Automatic Adjustment The automatic adjuster adjusts the brake pad clearance to compensate for pad wear. Each time the brake is applied, the system senses whether adjust- ment is required or whether running clearance between the pads and rotor is within the built-in tolerance. When the running clearance is greater than the built-in toler- ance as a result of pad or rotor wear, adjustment is re- quired. The automatic adjuster maintains a total nomi- nal pad -to -rotor clearance of 0.030 in. (0.75 mm). Operation Without Adjustment From the rest position, the air chamber push rod moves forward, rotating the operating shaft. When the pistons move forward through the built-in running clear- ance, the ball -ended drive pin starts to control the driv- ing side of the fork on the end of the adjuster shaft. Further movement of the air chamber push rod ro- tates the operating shaft, causing the adjuster shaft to rotate because the built-in clearance has been taken up. The outer drive sleeve, fixed to the adjuster shaft, rotates the inner drive sleeve through the clutch pack. The inner drive sleeve is linked to the intermediate gear by a unidirectional friction spring, which tries to ro- tate the tappets. However, the friction in the threads of the tappets and pistons increases due to he clamping force of the pads. This prevents the pistons and tappets from rotat- ing relative to one another. The pistons cannot rotate in the adjuster housing, and due to the high torque to turn the tappets, the clutch pack slips, preventing adjust- ment of the mechanism below the correct running clearance. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 a D Series Maintenance Manual Page 4c-9 Driven Figure 7. Caliper Sectional View 1302 Item Description 1 Short Slide in Oval Bushing 2 Housing Seal 3 Operating Shaft 4 Return Spring 5 Piston 6 Piston Head 7 Chamber Piston 8 Adjuster Shaft 9 Half Bearing 10 Roller 11 Tappet 12 Adjuster Stem 13 Long Slide Pin Bushing Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-10 D Series Maintenance Manual Operation With Adjustment When the running clearance is greater than the built-in tolerance as a result of pad or rotor wear, ad- justment is required. From the rest position, the push rod of the air chamber moves forward, rotating the op- erating shaft. As the pistons move forward beyond the built -In running clearance, the ball -ended drive pin starts to contact the diving side of the fork on the end of the adjuster shaft. Further operating shaft movement causes rotation of the adjuster shaft through the ball - ended drive pin. Driving through the clutch plates and the unidirec- tional friction spring, the intermediate spring rotates. Due to the excessive running clearance, the tappets now rotate in the pistons. The pistons cannot rotate and are wound out of their housing. When the pads contact the rotor, the damping force increases the thread friction in the tappets and pistons. The torque to turn the tappets increases and the clutch pack during the intermediate gear starts to slip, preventing further adjustment. The adjustment is not wound back during the return of the actuation mechanism. As the operating shaft returns to the brake's off position, the ball -ended drive pin travels back through the clearance in the fork on the end of the adjuster shaft. Driver Once the clearance is taken up, the adjuster shaft rotates in the reverse direction, rotating the inner drive sleeve through the clutch pack. However, in this direc- tion, the unidirectional friction spring cannot drive the intermediate gear, leaving the tappets and intermediate gear in the adjusted state. The system is then in the starting position. Manual Adjustment and De -adjustment ACAUTION Manual adjustment of the brake must only be made when changing the pads. No manual adjustments are required between pad changes. A manual adjuster stem runs in constant mesh with the gear form on the outside of the tappets. The end of the stem protrudes through a brake housing seal and is protected by an adjuster cover. (Refer to Caliper As- sembly in this section for adjustment and de -adjust- ment procedures.) Copyright 2013 - Motor Coach Industries Int'i, Inc. and its subsidiaries. All Rights Reserved. PIN 03-26-0219 Date September 2013 D Series Maintenance Manual Page 4C-11 fYan �IVlfllr0 � f\Be i �nrrrn r [, Figure 8. Exploded View 9 10 26to 2 23 11303 Item Description Item Description 1 Air Chamber 13 Long tide in 2 Slide Pin Cap 14 Piston Boot 3 Short Slide Pin Solt 15 Air Chamber Washer 4 Short Slide Pin 16 Air Chamber Nut 5 Bridge Bok 17 Visual Wear Indicator 6 Caliper Housing Assembly 18 Bridge 7 Slide Pin boot 19 Carrier Bolt 8 Visual Wear Indicator Spring 20 Washer 9 Pad Retainer 21 Torque Plate 10 Pad Retainer Bolt 22 Carrier 11 Adjuster Gear 23 Brake Pad 12 Long Slide Pin Bolt 24 Pad Spring Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Pae 4C-12 D Series Maintenance Manual Page Reliability Driven MAINTENANCE 5. If it is necessary to grind or machine brake linings, additional precautions should be taken Maintenance Schedule because contact with fiber dust is higher during A schedule for inspection, cleaning and adjustment these operations. In addition to wearing an of brake components must be established based on approved respirator, such work should be done in the specific coach use and brake wear characteristics. an area with exhaust ventilation. j . Non -asbestos brake linings may contain glass, mineral wool, aramid, ceramic or carbon fibers. Long-term exposure may cause pneumoconiosis, fibrosis or cancer. Avoid creating and breathing the dust from the non -asbestos brake linings. Use the following guidelines listed below should be followed to minimize exposure to non -asbestos brake lining dust and particles. 1. Whenever possible, work on brakes in a separate area away from other operations. 2. Always wear a respirator approved by NIOSH or MSHA during all brake service procedures. Wear the respirator from the removal of the wheels through assembly. 3. Never use compressed air or dry brushing to clean brake parts or assemblies. OSHA recommends using cylinders that enclose the brake. These cylinders have vacuums with high - efficiency (NEPA) filters with arm sleeves. If such equipment is not available, carefully clean parts and assemblies in the open air. 4. Clean brake parts and assemblies In the open air. During disassembly, carefully place all parts on the floor to avoid getting dust into the air. Use an industrial vacuum cleaner with a HEPA filter system to clean dust from brake parts. After using the vacuum, remove any remaining dust with a rag soaked in water and wrung nearly dry. 6. When cleaning the work area, never use compressed air or dry sweeping. Use an industrial vacuum cleaner with a HEPA filter and rags soaked in water and wrung nearly dry. Used rags should be disposed of with care to avoid getting dust Into the air. Use an approved respirator while emptying vacuum cleaners and handling used rags. 7. After working on the brake system, workers should wash their hands before eating or drinking. Work clothes should not be worn home. Work clothes should be vacuumed after use and then laundered separately, without shaking, to prevent getting fiber dust Into the air. To prevent serious eye injury, always wear eye protection when performing vehicle maintenance or service. Before inspecting or performing maintenance on the coach, observe the following conditions: 1. Park the vehicle on a level surface. 2. Block the wheels to prevent the vehicle from moving. 3. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PM 03-26-0219 Date September 2013 D Series Maintenance Manual Page 4c-13 Reliability Driven Inspection Light heat checking is very fine, tight cracks. Light Rotor Inspection heat checking is normal. A rotor with light heat check - ng can continue to be used. Heavy heat checking is When inspecting or relining the brakes, the rotor evident by surface cracks that have width and depth thickness should be measured and both surfaces in- and extend some distance. Replace the rotor if heavy spected for the following conditions. heat checking is observed. Cracks W7 A 11304 Figure 9. Rotor with Cracks A crack can extend through a section of the rotor. and, when heated through normal braking, they can open and separate. This may cause rapid lining wear. Replace the rotor. Heat Checking Figure 10. Rotor with Heat Checking Heat checking is caused by heat and appears as cracks in the surface of the rotor. There are two cate- gories of heat checking, light and heavy. Grooves or Scores 11306 Figure 11. Rotor Showing Grooves or Scores Check both sides of the rotor for deep grooves or scores. If the grooves or scores are not too deep, (max- imum depth not to exceed 0.02 in. (.5 mm)] the rotor may continue to be used. If the grooves or scores are deep, or when installing a new lining, refinish the rotor for replace it if the thickness is less 1.46 in. (37.1 mm)]. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-14 Bluing D Series Maintenance Manual I �t> Figure 12. Rotor with Blue Bands and Marks Blue marks or bands indicate that the rotor had be- come very hot. If blue marks or bands are present, use the troubleshooting guide to find and correct the cause of the problem. Rotor Thickness Measurement The rotor must be replaced if the thickness falls be- low the minimum of 1.46 in. (37.1 mm). Take the mea- surements at 0, 120, and 240 degrees. Damage to components can result it not replaced. (37 mm) 11308 Figure 13. Rotor Thickness Measurement A. Vented Rotor Item I Description I I Minimum Thickness 2 Micrometer Driven 1. Use a micrometer to measure the rotor thickness. if pads are being replaced, the rotor should also be replaced it the thickness is less than 1.46 in. (37.1 mm). 2. Check for uneven rotor wear. Use the pad retainer as a gauge and place it between the rotor surface and the carrier pad abutment. Check both the inboard and outboard sides of the rotor. If the pad retainer fits into the gap on either side, replace the rotor. Rotor Runout Measurement Attach a dial indicator to the caliper or axle frame. NOTICE The runout measurement should be taken from the center of the rotor braking surface. The endplay of the hubs should not be included in this measurement. 2. Check the internal runout of the rotor brak- ing surface. the runout should not exceed 0.02 in. (0.5 mm) through one full revolution of the rotor. 3. If the runout exceeds 0.02 in. (0.5 mm), check the wheel bearings for correct adjust- ment. Refer to Section 1 or Section 2 for adjustment procedure. Rotor Removal and Installation — Front and Tag Axle Removal 1. Park the vehicle on a level surface. Block the rear wheels to prevent the vehicle from moving. 2. Raise the vehicle so the axle is off the ground. Support the vehicle with safety stands. Do not use a lack to support the ve- hicle. 3. Remove the brake caliper assembly. Refer to Section 4 - Brakes and Air System. 4. Remove the wheel adapter. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 N D Series Maintenance Manual Driven 5. Remove the keeper from the PRO-TORQT" nut. Use a screwdriver to pry out the keeper arm from the groove on each side of the nut until the keeper is released. Meritor recom- mends replacing the keeper with a new one each time the PRO-TORQTm nut is removed to maintain the integrity of the locking mech- anism. 6. Use a 3.5 in. (89 mm) socket wrench to re- move the PRO-TORQT" nut. 7. Remove the thick washer. 8. Remove the rotor and unitized bearing as an assembly. Installation 1. Install in reverse order of removal. Removing a UWE with a Meritor Rotor Seized to the Hub 1. Park the vehicle on a level surface. Block the rear wheels to prevent the vehicle from moving. 2. Raise the vehicle so the axle is off the ground. Support the vehicle with safety stands. Do not use a jack to support the ve- hicle. 3. Remove the brake caliper assembly. Refer to Section 4 - Brakes and Air System. 4. Remove the wheel adapter. 5. Remove the keeper from the PRO-TORQTM nut. Use a screwdriver to pry out the keeper arm from the groove on each side of the nut until the keeper is released. Meritor recom- mends replacing the keeper with a new one each time the PRO-TORQTm nut is removed to maintain the integrity of the locking mech- anism. 6. Use a 3.5 in. (89 mm) socket wrench to re- move the PRO-TORQTm nut. 7. Remove the thick washer. 8. Remove the rotor and unitized bearing as an assembly. 9. Place the rotor and hub assembly flange face down on a bench or the floor. Date September 2013 Page 4C-15 10876 Figure 14. Inner Portion of Hub Item Description 1 -Rotor - 2 Hub 3 Saturate with penetrating oil 10. Apply and saturate the inner portion of the hub barrel with penetrating oil. Aerol(roil is preferred. Let the oil soak for at least 30 minutes. 1 Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury. 11. Once the soak is complete, place the rotor into an arbor press with the back face of the rotor facing down and supported correctly. Copyright 2013 - Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. PM 03-26-0219 Date September 2013 Page 4C-16 D Series Maintenance Manual Reliability Driven 10877 Figure 15. Tool Position Item Description t 1 Press 2 1 Tool 12. Place the tool on top of the rotor and hub as- sembly. (Refer to Service Tools) 13. Apply pressure until the hub assembly is free from the rotor. 14. Apply Loctite(D 620 retaining compound to the new hub -to -rotor bolts. 15. Use the new hub -to -rotor bolts and washers to attach the new rotor to the hub. Be careful not to damage or move the hub -mounted tone rings during new rotor installation. \ I i l I 10879 Figure 16. 10 -Bolt Pattern 10880 Figure 17. 8-13olt Pattern 16. Tighten the hub -to -rotor bolts in a crisscross patten to the correct torque. (Refer to Hub and Rotor Torque Chart.) 17. Ensure that all bolt heads do not protrude past the wheel -to -hub mounting surface. 18. Install the hub and rotor assembly to the ax- le. Ensure the rotor braking surfaces are tree of oil, grease, and other contaminants. 19. Install the caliper assembly and brake pads. Adjust the brake pad -to -rotor clearance. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Reliability Other' D Series Maintenance Manual Page 4C-17 Acton Specification Heavy heat checking requires the rotor be replaced, regardless of thickness of Check for heat checking grooving. Use the pad retainer. Place it between the rotor surface and the carrier pad Check for uneven rotor wear abutment. Check both the inboard and outboard sides of the rotor. If the pad retainer fits into the gap on either side, replace the rotor. Use a micrometer or vernier caliper. This is measured at the center of the pad Minimum pad thickness = 0.12 in. near the gap. It is best to take at least two measurements. Subtract the (3.0 mm) thickness of the pad backing plate. This is normally 0.319 in. (8.1 mm). Minimum rotor thickness = 1.46 in. Use a micrometer or vernier caliper. Take three measurements at 0 degrees, (37.1 mm) 120 degrees, and 240 degrees. When replacing pads, minimum rotor Use a micrometer or vernier caliper. Take three measurements at 0 degrees, thickness - 1.54 in. (39.1 mm) to allow for 120 degrees, and 240 degrees. wear during pad fife Use the long (pointed) end of a dial caliper. Place it in the radial direction Maximum rotor groove depth = 0.02 in. across the rotor surface and measure how far the point protrudes. If a groove is (.5 mm) found to be deeper than 0.02 in. (.5 mm), and the rotor is of sufficient thickness, have the rotor turned. Minimum rotor thickness measured Subtract the measurement of the deepest groove from the minimum rotor across any groove(s) =1.46 in. (37.1 mm) thickness. If this groove is aligned with another deep groove on the opposite regardless of pad replacement side, subtract the sum of the groove depths from the minimum rotor thickness. Use a dial indicator. Attach the magnet to the axle frame. Turn the rotor one full Maximum runout = 0.02 in. (.5 mm) revolution and note the lateral runout. Do not include the end play of the hub through one full revolution bearings in this measurement. If the runout is greater than 0.02 in. (.5 mm), check the wheel bearings for correct adjustment. Figure 18. Check for Uneven Rotor Wear 42873 I item I Description J Replace Copyright 2013— Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-260219 Date September 2013 Pae 4C-18 D Series Maintenance Manual 9 Reliability Driven Disc Brake Pad Contact Surface Inspection In normal operating conditions the brake assembly will slide freely with even pad wear. It is possible that damaged or corroded brake components could restrict NOTICE free movement of the brake pads. Meritor WABCO recommends that the attached inspection be conducted at the following intervals; brake pad change, when significant corrosion build-up occurs and when brake drag Is felt or experienced. Q CAUTION Refer to Section 3, Lifting, In the MCI Maintenance Manual, for the basic procedures and safety precautions that must be followed before a coach Is lifted. Refer to Meritor WABCO DiscPlus EX225 Air Disc Brake Maintenance Manual (MM- 0467) available at www.meritorwabco.com. This document applies to all vehicles fitted with DiscPlus EX225 Brakes. Vehicles operating in areas where road salts or de-icing materials are used are particularly subject to the conditions described in this document. The following reinforces procedures avail- able in MM -0467, DiscPlus EX225 Air Disc Brake Maintenance Manual. Meritor WABCO recommends that an inspection of the disc brake pad contact surfaces is conducted at the following intervals: Pad change When significant corrosion build up occurs When concern of residual brake drag is present Procedure Park the vehicle on hard ground and chock the road wheels. Where necessary, to gain access, jack up the axle and fit suitable axle stands securely. 1 To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal Injury and damage to components can result. Copyright 2013 - Motor Coach Industries Infl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 D Series Maintenance Manual neliabilifv Driven Date September 2013 Page 4C-19 Figure 19. Pad Abutment Corrosion (Before and After Clean Up) 2. Remove the brake pads. I Never use an air line to blow dust from the brake disc area. If inhaled any form of dust can irritate the throat and lungs or result in injury. When ever possible remove dry brake dust with a vacuum brush. Alternatively wipe the areas with a damp cloth; never try to accelerate drying time by using an air line. 3. Use a vacuum brush or damp cloth to re- move the dirt and dust from the carrier brake pad contact surfaces. 4. Inspect the carrier for signs of damage, wear or surface corrosion. Pay particular at- tention to the pad abutment surfaces. If there is excessive wear or damage to the abutments, it may be necessary to replace the caliper assembly. Figure 20. Surface Cleaning (Before and After Clean Up) 5. While wearing suitable eye protection re- move all traces of scale, dirt, etc from the pad apertures/abutment faces and around the edge of the rotor, particularly any that encroach onto the braking area. These may restrict free movement of the pads. A scraper or old screwdriver supported on the brake body while the rotor is rotated will remove most of the corrosion. Finish off it necessary with emery cloth. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-20 D Series Maintenance Manual Reliobilily Driver 6. Inspect the pad retainer as follows: a. Inspect the pad retainer for defor- mation by resting a straight edge against it. A deformed pad retainer (more than 0.5 mm gap) could result in incorrect pad spring loading. Re- place a deformed pad retainer with service kit. b. Inspect the pad retainer for corrosion buildup where the pad spring con- tacts it. An excessively corroded re- tainer could restrict free pad movement. Scrape clean or replace a severely corroded pad retainer. 7. Refit brake pads. Caliper 11309 Figure 21. Caliper Adjustment 1. Park the coach on a level surface and block the wheels to prevent the vehicle from moving. 2. Apply air pressure to release the parking brake. 3. Remove all air from the system. Cage and lock the spring brake. 4. Attach a dial indicator to the torque plate or axle frame. Take the dial reading from the slide pin cap. 5. Check brake adjustment by sliding the cali- per back and forth along the slide pins. If the caliper moves more than 0.08 in. (2.0 mm), the brake is out of adjustment, requiring ad- ditional inspection or replacement. Copyright 2013 - Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. PSN 03-26-0219 Date September 2013 M D Series Maintenance Manual Page 4C-21 r Driven Lining Wear 11310 Figure 22. Visual Wear Indicator Item Description 1 1 Visual Wear Indicator The visual wear indicator shows approximately how much lining material remains. If the indicator pro- trudes less than 0.16 in. (4.0 mm) from the casting, the pads may require replacement. Rotor Visually inspect the rotor for signs of cracks, deep grooves, blue marks, and heat checking. Refer to Rotor in this section for additional information. Air Chamber Inspect air chamber to verify that caliper mounting bolts and air lines are securely fastened and not dam- aged. Caliper Assembly Removal I , Never disassemble the spring brake chamber. Serious personal Injury or death could result. Wear eye protection. During parts of this inspection, one person will be in the cab and the other will be performing tests at the chamber. Ensure that there Is a reliable communication system established. TAKE EXTREME CARE to avoid personal injury. Before working on or around a spring chamber, Inspect the chamber for structural damage. If damage is suspected, do not attempt to cage the brake. The unit will have to be removed from the vehicle and disarmed following MGM's recommended procedures. Never disconnect a pressurized air line. Never remove a component or plug unless system pressure has been depleted. Do not exceed recommended air pressures. Copyright 2013 - Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-22 D Series Maintenance Manual Cage the spring chambers. 11312 Figure 23. Air Chamber Removal 2. Carefully remove the air hoses from the air chamber. 3. Remove the air chamber nuts and washers. 4. Remove the air chamber assembly from the brake caliper and inspect the air chamber. 5. Cover the exposed air chamber mounting aperture with tape to prevent debris from entering the caliper housing assembly. Driver 6. De -adjust the caliper and remove the brake pads. Refer to Brake Pad Removal in this section. 111 Figure 24. Carrier Bolt Removal 7. Remove the carrier bolts and washers. Carefully remove the caliper assembly from the axle. Installation Locate the caliper assembly over the rotor. NOTICE The caliper mounting bolts on the front and tag axles should be the same. 2. Align the carrier bolt holes and assemble the caliper to the torque plate with the carri- er bolts. Tighten the carrier bolts and torque to 400-500 ft -Ib (543-677 Nm). Copyright 2013 - Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 W D Series Maintenance Manual Page 4C-23 Driven Figure 25. Perforated Transit Tab Removal Item Description 1 Tab 2 Tab Removed ACAUTION If applicable, before installing air chamber onto the caliper assembly, ensure the perforated transit plug is removed from the caliper chamber seat by pulling the tab. 3. Check caliper assembly to verity it slides by hand. 4. Install the air chamber on the caliper assem- bly. Refer to Air Chamber Installation in this section. 5. 5. Install the brake pads and set the initial brake pad -to -rotor clearance. Refer to Brake Pad Installation in this section. Brake Pads Brake De -Adjustment NOTICE it Is important to note that manual adjustment of the brake must only be made when changing the pads. No manual adjustments are required between pad changes. 1 11313 11314 Figure 26. Adjuster Cover Item Description 1 1 Adjuster Cover i. Remove the adjuster cover. A CAUTION Always use a suitable wrench to de -adjust and adjust the brake. Never use air or power tools. Damage to brake components will result. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-24 D Series Maintenance Manual 3. If the manual adjuster does not rotate in ei- ther direction, replace the caliper assembly and chamber assembly. Adjustment Check ACA UTION Before checking for correct brake adjustment, verity that the wrench movement will not be obstructed by the air chamber, hoses or other components. Damage to the brake can result. ® 1. De -adjust the brake using a 10 mm wrench. TRotate the adjuster stem one quarter turn counterclockwise. ® -0.0 '11315 Figure 27. Brake Adjustment A. De -Adjust B. Adjust Figure 28. Adjuster Stem 11316 Item I Description 1 Adjuster tem 2. De -adjust the brake using a 10 mm wrench. Rotate the adjuster counterclockwise until the adjuster stem stops. NOTICE De -adjustment requires more force than adjustment; 30 ft -lb (40 Nm) must not be exceeded in either direction. 11317 Figure 29. Adjustment Check 2. With the wrench in place on the stem, actu- ate the brake one time. a. If the wrench rotates clockwise when the brake is actuated, the ad- juster mechanism is working cor- rectly. b. If the wrench does not rotate clock- wise when the brake is actuated, the adjuster mechanism is not working correctly. Replace the caliper assem- bly. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved, P/N 03-26-0219 Date September 2013 11i1� D Series Maintenance Manual Page 4c-25 Reliability Driven Removal 5. Remove the inboard brake pad for the cali- per assembly and mark the pad as inboard. Figure 30. Pad Retainer Removal Item Description 1 Pad Retainer A CAUTION Replace pads on both brakes of a single axle. 1. Remove the pad retainer bolt and the pad retainer. 2. Inspect the pad retainer. If the retainer is bent or damaged, replace the pad retainer. 3. Remove the pad springs. 11319 Figure 31. Outboard Pad Removal 4. Remove the outboard brake pad for the cali- per assembly and mark the pad as out- board. rC 1 ■ Remove dry brake dust with a vacuum brush or wipe the areas with a damp cloth. Never use an air line to blow dust from the brake and rotor area. Never try to accelerate drying time by using an air line. Serious personal injury and damage to components can result. 6. Use a vacuum brush or a damp cloth to re- move the dirt and dust from the carrier brake pad contact surfaces. Figure 32. Pad Abutment Location Item Description 1 Pao ADUTment 7. Inspect the carrier for signs of damage or wear. If there is excessive wear or damage to the pad abutments, caliper assembly re- placement may be necessary. 8. Inspect brake pads for excessive grooving or cracked friction material. Check friction material for looseness or detachment from backing plate. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-26 D Series Maintenance Manual 0.12 in. (3 mm)—►I � 0 7� 2, 11321 Figure 33. Brake Pad Measurement Item Description Minimum Lining Thickness, t 0.12 in. (3 mm) 2 Measurement Location 3 Measurement Location 9. Measure the lining thickness from the center of the pad. Replace brake pad assemblies before the lining thickness wears to 0.12 in. (3 mm). NOTICE The minimum thickness is 0.12 in. (3.0 mm), measured at the center of the pad near the gap, less the thickness of the backing plate. This measurement is normally 0.32 in. (8.1 mm). 10. Inspect pad springs and replace it bent, cracked or broken. Figure 34. Slide Pin Boot Fit A. Correct Driven 11. Verify the caliper slides freely on the slide pins. Be careful not to trap fingers while checking the sliding action. if the caliper does not slide, check the slide pin boots for damage and verify they are seated correctly. 11323 Figure 35. Piston Boot Fit A. Correct 12. Inspect the piston boots. Boots must be free of damage and correctly seated. 13. If any of the caliper slide pin boots or piston boots are damaged or unseated, they must both be replaced. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Driven Slide Pin Bushings D Series Maintenance Manual NOTICE The following procedure should be performed with the brake assembly installed on the vehicle and the pads removed. Tangential Test 2. 11324 Figure 36. Slide Pin Bushing Tangential Test Item Description 1 Hold The Caliper Here 2 Dial Indicator 3 Short Slide Pin Centerline 4 Swivel The Caliper Pull the caliper housing outward toward the wheel flange. Attach a dial indicator to the hub in line with the centerline of the short slide pin. Hold the caliper to prevent movement. Swiv- el the caliper until it stops in one direction. Set the gauge to zero. Date September 2013 Page 4C-27 Figure 37. Caliper Housing Movement 3. Move housing into the opposite direction un- fil it stops. The maximum acceptable read- ing is 0.118 in. (3 mm). If the reading is more than 0.118 in. (3 mm), replace the cal- iper assembly. Recital Test Figure 38. Slide Pin Bushing Radial Test 1. Attach a dial indicator to the vehicle hub and set it against the caliper. 2. Position the brake in the half -worn pad posi- tion. This position is set when a gap of ap- proximately 0.8 in. (20 mm) exists between the rotor and bridge. Hold the caliper at the outboard pad edge and by the air chamber. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Item Description 1 Dial Indicator 2 Caliper 3 Hold The Caliper Here 1. Attach a dial indicator to the vehicle hub and set it against the caliper. 2. Position the brake in the half -worn pad posi- tion. This position is set when a gap of ap- proximately 0.8 in. (20 mm) exists between the rotor and bridge. Hold the caliper at the outboard pad edge and by the air chamber. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-28 D Series Maintenance Manual Reliability Driven - 1 riven 1327 Figure 39. Gauge Adjustment 3. Push the brake down by hand as far as pos- sible and set the gauge to zero. 4. Pull the caliper up as far as possible to allow the caliper to slide. The maximum accept- able reading is 0.078 in. (2 mm). If the read- ing is greater, replace the caliper assembly. Installation 11328 Figure 40. Outboard Pad Installation ACAUTION Ensure the pads are installed with the friction material is facing the rotor. Installing them improperly can result in damage to the components. 1. Slide the caliper outward. Install the outboard pad and spring into the outboard side of the caliper. 2. Slide the caliper inward. Install the inboard pad and spring into the inboard side of the caliper. Figure 41. Pad Retainer Installation Item Description 1 Pad Retainer 3. Install the pad retainer and pad retainer bolt. Tighten the bolt and torque to 25-30 ft -Ib (34-40 Nm). NOTICE If the pad retainer is being replaced, do not reuse the original pad retainer bolt. Instead, use the bolt supplied with the kit. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 W D Series Maintenance Manual Page 4C-29 Driven A CAUTION The Initial brake to pad -to -rotor clearance must be adjusted or an inefficient, dragging brake can occur, resulting in damage to components. Always set the initial brake pad -to -rotor running clearance with the air chamber installed to prevent damage to components. 4. Set the initial pad -to -rotor running clear- ance. a. Remove the adjuster cover. b. Use a 10 mm wrench to rotate the manual adjuster stem clockwise so that The brake pad -to -rotor clearance is zero. C. De -adjust the manual adjuster stem one half turn counterclockwise to set the initial running clearance. Rein- stall the adjuster cover. Piston Boots 1. Cage the spring chambers. 2. De -adjust the caliper and remove the brake pads. Refer to Brake Pad Removal in this section. 3. Rotate the manual adjuster stem clockwise until the piston assemblies are extended ap- proximately 2 in (50 mm). Figure 42. Piston Boot Removal Item Description 1 I Piston Hoot 2 1 Piston Head 4. Remove the piston boots. Do not remove piston heads from the assembly. 5. Clean the piston heads and housing with a suitable brake cleaner. 6. Check condition of the piston shafts. If ex- cessive corrosion or wear is present, re- place the caliper. Installation A CAUTION When installing new piston boots, do not use grease to aid assembly. Using grease may result in damage to the piston boots. Lightly lubricate the piston shafts. Use only the grease supplied with the replacement components and kits. Figure 43. Piston Boot Installation Item Description 1 Piston Head 2 2 Tab 2. Install piston boots: a. Carefully install a new piston boot over a piston head. The larger seal diameter with the tab goes over the piston head first. Copyright 2013— Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-30 D Series Maintenance Manual 11332 Figure 44. Piston Head Groove Item I Description 1 1 Piston Head Groove b. Carefully install piston boot into the piston head groove. 11333 Figure 45. Piston Retainer Groove item Description 1 1 Piston Head Groove C. Stretch the piston boot and pull it over the housing assembly retainer groove. d. Rotate the piston boot to ensure the boot beads are correctly seated in the retainer groove. Driver 3. Repeat the procedure and install the second piston boot. 4. Rotate the manual adjuster stem counter- clockwise and de -adjust the piston assem- blies. NOTICE It may be necessary to lift the piston boot tab and release air Inflating the boot. 5. Install the brake pads and set the initial brake pad -to -rotor clearance. Refer to Brake Pad Installation in this section. NOTICE If other caliper components must be replaced, replace the components before installing the pads. Refer to the appropriate procedures in this section. Caliper Bridge The following procedure involves the removal and disassembly of the caliper bridge and its components. If complete disassembly is not required, proceed to the appropriate assembly sequence and continue from there. Caliper components replaced in this procedure: • Housing assembly • Slide pin boots • Slide pins Caliper Bridge Removal Remove the caliper assembly from the axle. Refer to Caliper Assembly Removal in this section. NOTICE Removal of the caliper assembly is unnecessary if there is adequate room in the wheel well to service the assembly. Copyright 2013 -Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26.0219 Reliability Date September 2013 D Series Maintenance Manual Page 4C-31 0 I \',—, I 1 1 11334 Figure 46. Bridge Bolt Removal 2. Remove the four bridge bolts. Discard the bolts; they must be replaced when removed. Figure 47. Bridge Removal 3. Carefully remove the bridge. Caliper Housing Removal Figure 48. Housing Removal Remove the caliper housing from the slide pins. Slide Pin Boots Removal Figure 49. Carrier inspection Points Item Description 1 Slide Pins 2 1 Pad Abutment 1. Remove the slide pin boots from the housing assembly. Discard the boots. 2. Clean and inspect the carrier for damage and wear with special attention to the abut- ment areas and the slide pins. a. If there is damage or excessive wear to the slide pins, replace the slide pins. Refer to Slide Pin Boots Installation. b. If there is damage or excessive wear to the carrier, replace the carrier as- sembly. Refer to Carrier Assembly Installation. 11338 Figure 50. Slide Pin Removal Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-32 D Series Maintenance Manual NOTICE Note locations of the long and short slide pins before removal. 3. Remove the slide pin bolts. It necessary, tap the slide pins with a rubber or soft metal hammer lightly to break the seal. Slide Pin Installation 1. Clean the slide pin contact areas and threaded holes in the carrier and check for wear. NOTICE To ensure the caliper functions correctly, the long and short pins must be installed correctly on the carrier. Once installed, the slide pins require no adjustment. 2. Install new slide pins and secure with the correct slide pin bolts. Tighten the bolts and torque to 310-332 ft -Ib (420-450 Nm). Slide Pin Boots Installation Lightly lubricate the slide pins and the inside of the new slide pin boots. Use only the grease supplied with the replacement components and kits. 11339 Figure 51. Slide Pin Boot Installation Item Description I I Retainer Groove Driven Figure 52. Slide Pin Boot Installation 2. Slide the new slide pin boots over the slide pins. Ensure the slide pin boot bead is seat- ed correctly in the slide pin retainer groove. Caliper Housing Installation 1 11341 Figure 53. Slide Bore Locations 1. Lubricate the slide pin boots and the slide bores in the housing assembly. Use only the grease supplied with the replacement components and kits. Figure 54. Caliper Housing Installation Copyright 2013 - Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 1 i D Series Maintenance Manual Page 4C-33 Reliability Driven _ 2. Carefully slide the housing assembly onto the slide pins. Be careful not to damage the slide pin boots during installation. 3. Install the slide pin boot beads into the housing retainer grooves. 4. Ensure the slide pin boots are correctly in- stalled on both the carrier and housing re- tainers. I Use a brass or synthetic mallet for assembly and procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off. Serious personal injury and damage to components can result. 5. If installing a new housing, carefully tap one of the new end caps into the caliper housing assembly until it retains itself. NOTICE Use the correct tool size to tap the end cap Into the bore, 0.069--0.088 In. (1.75-2.25 mm) for the short slide pin side; 0.228-0.251 in. (5.79-6.38 mm) for the long slide pin side. The caps must be installed to the correct depth. If either cap is pressed into the bore below the minimum dimension, the full movement of the housing assembly will be restricted. 11343 Figure 55. Short Slide Pin End Cap Clearance Figure 56. Long Slide Pin End Cap Clearance 6. Check the housing assembly to ensure it slides by hand on the slide pins. Slide the assembly back and forth several times to check for smooth movement. NOTICE The boots are correctly installed if they collapse from the changes within the slide pin mechanism. Caliper Bridge Installation Figure 57. Bridge Installation Position the bridge against the caliper housing assembly and install four new bridge bolts. Copyright 2013 - Motor Coach Industries Incl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-34 D Series Maintenance Manual Figure 58. Bridge Boit Installation 2. Tighten M16 bolts to 221-253 ft -Ib (300-350 Nm). TESTING Test procedure to periodically check actuators fitted to DiscPlus E%225 air disc brakes. The following steps applies to all vehicles fined with DiscPlus 225 Brakes and more specifically, vehi- cles which operate in areas where road salts or de-icing materials are used. Meritor WABCO recommends that an inspection of the internal condition of the brake and brake actuator be conducted on a regular basis. The frequency of this inspection is based on fleet experience. Driven- Although riven Although the brake and brake actuator are sealed corrosion in the air chamber seal area could lead to corrosion of the brake mechanism. Meritor WABCO has developed the following procedure to inspect for such damage without the need to remove the brake ac- tuator. Park the vehicle on hard ground and chock the road wheels. Where necessary, to gain access, jack up the axle and fit suitable axle stands securely. I To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by lacks. Jacks can slip and fall over. Serious personal Injury and damage to components can result. 44128 Figure 59. Disassemble Brake Assembly 44129 Figure 60. Disassemble Brake Assembly Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 N D Series Maintenance Manual Driven l Never use an air line to blow dust from the brake/ disc area. If inhaled any form of dust can Irritate the throat and lungs or result in Injury. When ever possible remove dry brake dust with a vacuum brush. Alternatively wipe the areas with a damp cloth; never try to accelerate drying time by using an air line. Remove any dirt from the brake assembly, ensure the rubber dust excluders are not damaged. 44130 Figure 61. Remove Wear Sensor Plug 3. Remove the wear sensor plug retaining bolt. Carefully lever out the sensor plug and place to one side with the boll for refitment later. 44131 Figure 62. Clean Sensor Access Hole Date September 2013 Page 4C-35 44132 Figure 63. Inspect Sensor Access Hole Figure 64. Vacuum Test Adapter Plug and Grease 4. Clean the sensor/switch access hole and mounting face on the housing with a clean cloth and ensure no debris is allowed to fall into the exposed aperture in the housing. Lightly grease the O-ring seals on the vacu- um test adapter plug. Fit the adapter plug in- to the housing and press into place. Fit the retaining screw and tighten down, 24.3-29.5 ft -Ib (33-40 Nni ACAUTION Use only the grease supplied with replacement components/klts, or that is specified by the vehicle manufacturer. Under no circumstance should any other type of grease be used. Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-36 D Series Maintenance Manual NOTICE Ensure the adjuster cover retaining strap is not trapped under the adapter plug. 44134 Figure 65. Conical Connectors 44135 Figure 66. Adapter and Connector Fitted 5. Using a suitable vacuum tester, such as a Mityvac, select the conical connector from the test kit that fits the hole in the adapter plug and insert it in the adapter plug. Reliability Driver( 44136 Figure 67. Vacuum Tester in Position 6. Connect the vacuum tester to the connector using the tubing supplied with the vacuum tester. T Hold the conical connector firmly in place in the test adapter plug to ensure a good seal is made between the connector and the plug. 8. While holding the connector, actuate the tester, observing whether a vacuum is gen- erated. If a vacuum is generated, do not ex- ceed a value of -5 in. Hg. Stop pumping and observe whether the vacuum is held or starts to decay. If a vacuum is generated and held, proceed to Section A. If a vacuum decays or no vacuum is gener- ated, then proceed to Section B. Section A It a vacuum is generated and held, then no further investigation needs to be made. Le- ver out the test adapter. Lightly grease the O-ring seal on the wear sensor plug, and refit to housing. NOTICE Ensure the adjuster cover retaining strap is not trapped under the adapter plug. Flt the retaining screw and tighten to a torque value of 24.3-29.5 ft -lb (33-40 Nm). Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 W D Series Maintenance Manual Page 4C-37 Driven- 9/o "� 44137 Figure 68. Corrosion on Ball End of Actuator and Liner Part of Seal t.. 44138 Figure 69. Corrosion Inside the Brake Housing Section B If no vacuum is generated or the vacuum decays, then this indicates the air chamber internal boot is compromised the air actua- tor may be removed from the brake for fur- ther inspection. In these circumstances, the actuator must be replaced. Visually inspect the actuator -mounting ap- erture on the caliper housing assembly. If there are signs of water entry and corro- sion, replace both the caliper housing and air actuator. When fitting a service replacement caliper housing and air actuator, refer to the MM -0467 for the detailed procedure. 9. After conducting steps described in either Section A or Section B, under the previous Step 8, ensure that the brake and air actua- tor are working correctly by performing a brake adjustment inspection. Brake Adjustment Inspection A CAUTION Before you check for correct brake adjustment, verify that the wrench will not be obstructed by the air chamber, hoses or other brake or axle components. Damage to the brake can result. Figure 70. Rotate Clockwise 1. To check for correct brake adjustment, de - adjust the brake by using a 10 mm wrench to rotate the adjuster stem one-quarter turn COUNTERCLOCKWISE. 2. With the 10 mm wrench on the adjuster stem, actuate the brake one time. If the wrench rotates CLOCKWISE when you actuate the brake, the adjuster mech- anism is working correctly. If the wrench does not rotate CLOCK- WISE when you actuate the brake, the adjuster mechanism is not working correct- ly. Replace the caliper housing assembly per procedure outlined in maintenance manual MM -0467. 3. Once completed, charge the system with air. Refit the road wheels, remove the axle stands, and lower the vehicle to the ground. NOTICE Before driving the vehicle or applying the park brake, apply the service brake five times at low pressure to ensure correct adjustment of the pads. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-38 D Series Maintenance Manual Reliability Driven TROUBLESHOOTING Condition Cause Correction Brake drag. Incorrect initial adjustment. Readjust to set the record pad -to -rotor Incorrect pad -to -rotor clearance. clearance. Spring or service brake not releasing Vehicle air system malfunction. Check for correct operation of air system or air chamber. Repair or replace parts as required. Brakes not releasing. Check for damaged slide pin boots. If the caliper will not move back and forth by hand with the linings removed, replace the caliper assembly. Check for water entry or a seized operation shaft. Replace the caliper assembly and air chamber. Air line too short. Replace the air line. Short brake pad lining life. Brake drag. Refer to Brake Drag condition above. Caliper seized or sticking on slide pins. Check for damaged slide pin boots. If the caliper will not move back and forth by hand with the linings removed, replace the caliper assembly. Damaged rotor surface. Check for cracks or heavy heat checking. Refer to inspection procedure for rotor in this section. Replace rotor if damage exceeds specification. Vehicle overload. Do not exceed the weight limitations specified on vehicle identification plate. Companion brakes do not work Inspect companion brakes and air system. correctly. Adjust or repair as required. Smoking brakes. High brake temperature. Refer to Brake Drag and Short Brake Pad Lining Life conditions above. This can be a temporary situation new or low mileage brakes. Contamination such as oil, grease, Inspect the hub seal and replace as required. undercoating, paint, etc. on the linings Clean the rotor and caliper assembly. or rotor. Replace the pads. Poor stopping power: Long stopping distances. Poor driving feel. Vehicle air system malfunction. Correct the air pressure at the chamber inlet. If necessary, have the system evaluated by a brake system specialist. Contamination such as oil, grease, Inspect the hub seal and replace as required. High brake pressure. Vehicle pulls to one side. undercoating, paint, etc. on the linings Clean the rotor and caliper assembly. or rotor. Replace the pads. Brakes out of adjustment. Readjust the set and correct pad -to -rotor clearance. Vehicle overload. Do not exceed the weight limitations specified on vehicle identification plate. Incorrect brake pads installed. Replace the brake pads. Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PIN 03-26-0219 Date September2013 D Series Maintenance Manual Page 4C-39 TROUBLESHOOTING (CONTINUED) Condition Cause Correction Brake noise. Incorrect pad installation. -Correct pad installation. ll necessary, replace the pads and rotor. Brake pads not free to move in the caliper. Check for corrosion or debris on the pads or carrier abutments. Clean or replace the pads and abutments if necessary. Worn brake pads. Check lining thickness and replace the pads if necessary. Brake component attachments are not installed to specification. Check for loose connections and fasteners. Tighten the connections and fasteners to the specified torque. Rotor cracks or excessive runout. Refer to inspection procedure for rotor in this section. Replace rotor if damage exceeds specifications. Pad spring damaged or not installed. Replace pad spring It damaged, or install if missing. Incorrect pads installed. Replace the pads. Bent or loose pad retainer. Replace or lighten the pad retainer. Copyright 2013 - Motor Coach Industries Int'l, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Date September 2013 Page 4C-40 D Series Maintenance Manual TORQUE CHART ee)♦Ilryi -reS111W , , Figure 71. Torque Callouts kern Descriptlon Torque Value Range Ft -Lb Nm 1 Pad Retainer Bolt 25-30 34-40 2 Carrier Bolt 400-500 543-677 3 Bridge Bolt 221-253 300-350 4 Slide Pin Bolts 310-332 420-450 5 Hub -to -Rotor Bolt, Drive (not shown) 155-195 210-264 6 Hub -to -Rotor Bolt, From, Tag (not shown) 165-190 224-257 7 Air Chamber Nut, Initial 59-75 80-100 8 Air Chamber Nut, Final 133-155 180-210 9 Chamber Release Tool Bolt (not shown) 5-11 7-15 Driven Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 Reliability Driven' ATTACHMENT J DIESEL ENGINE/TRANSMISSION INFORMATION Reliability Driverf POWERPLANT CUMMINS ISX 2013 EPA CERTIFIED ENGINE The Cummins ISX 11.9 liter engine, or approved equal will be four-cycle, six -cylinder, turbo- charged with an operating range of 700 rpm to 2100 rpm. The engine power rating will be 425 HP (317 kW) with a maximum torque curve of 1450 ]b. -ft (1,968 Nm) at 1,200 rpm. The patented Variable Geometry Turbocharger (VG Turbo), with only one moving part in the exhaust stream, constantly adjusts to deliver the precise amount of air for optimal performance at every rpm, resulting in improved throttle response. The ISX meets 2013 EPA emissions requirements. The Cummins ISX engine shall have Idle Control that manages idling time and improves fuel economy. The engine shall also have a starter Lockout system that provides additional engine/starter protection by preventing the starter to engage when the engine is running. The Cummins ISX engine shall use an engine brake to turn the energy -producing engine into an energy -absorbing compressor, extending service brakes and tire life. This engine brake shall be controlled by an ergonomically accessible switch. The engine will have built-in diagnostics to ensure that all components are operating properly. If a system component fails, the operator will be alerted to the condition via a dashboard mounted "Check Engine" and/or "Stop Engine" light. The Engine Protection system shall regulate engine rpm to reduce the risk of progressive damage when a severe fault code is logged. The electronic hardware and software on the ISX shall use a common architecture with all the latest diagnostics, maintenance monitoring and engine protection features with customer selectable shutdown. The entire system shall be capable of communicating with the electronically controlled transmission. The primary objective of the system is to provide the capability for the electronic engine controls to reduce power by command of the transmission in the event of transmission malfunction (low oil level/pressure; coolant temperature, etc.). The engine electronic control module shall be constructed as a weatherproof enclosure on the engine that is protected from the environment. Engine mounted components (excluding wiring connectors) may be exposed to steam cleaning and pressure washing. The engine shall be equipped with fast idle (950 RPM) and be driver controlled. The devices shall activate only with the transmission in neutral and parking brake applied. This device may be used to help meet the requirements of coach air conditioning cool down. The engine starter shall be protected by an interlock that prevents its engagement when the engine is running. The starter shall be prevented from engaging when the transmission selector is in any position other than neutral. Reliability Driven POWER REQUIREMENTS The propulsion system and drive train shall provide power to enable the coach to meet the defined acceleration, top speed, and gradability requirements. Sufficient excess power shall be available to operate all accessories without jeopardizing coach performance or safety parameters. TOP SPEED The coach shall be governed at 72 mph (116 kph) road speed, for emergency and passing maneuvers, on a straight, level road at SLW. GRADABILITY Gradability requirements shall be met on grades with a surface friction coefficient of 0.3 and above at SLW with all accessories operating. The standard configuration power plant shall enable the coach to maintain a speed of 44 mph (71 kph) on a 2 -percent grade and 7 mph (11 kph) on a 16 -percent grade. ACCELERATION Vehicle shall accelerate from 0 to 15 mph (0 — 24 kph) in five seconds, with the coach at S.L.W. OPERATING RANGE The operating range of the coach run on the design operating profile shall be at least 450 miles (724 km) on a single fill -up of diesel fuel. OPERATING PERFORMANCE Speed, gradability, and acceleration performance requirements shall be met at, or corrected to, 85 degrees F (29° C), 29.00 inches (74 cm) Hg, dry air. Performance degradation at conditions other than the test standard shall not exceed 1 % for each 3 degrees F/C and 4 % for 1,000 feet (305 m) of altitude above the standard. POWERPLANT MOUNTING AND ACCESSORIES MOUNTING The powerplant shall be mounted in a compartment in the rear of the coach. All powerplant mountings shall be mechanically isolated to minimize transfer of vibration to the body structure. Clamps required for securing or supporting lines shall be rubber or plastic coated and properly sized for the line being clamped. Reliability Driven` TRANSMISSION The transmission shall be an Allison B500 six speed transmission, equipped with Allison Transmission Electronic Controls (Gen. IV) or approved equal. Maximum input horsepower shall be 550 horsepower. Maximum input torque capability shall be 1650 pound feet of torque. The transmission shall have a one stage, three element, polyphase torque converter and a lock up clutch with a torsional damper. The transmission shall be fully automatic with six forward gear ratios. Shift calibration shall be set so that shifts shall be smooth under all operating conditions. The transmission shall only have one maintenance dipstick, and no other secondary service lane dipsticks. The transmission will also include a Probalyzer, or approved equal, brass Mini -gauge plug to permit transmission fluid analysis sampling. The Allison B500 Gen IV transmission shall be filled with synthetic transmission fluids that meet Allison TES -295 specification and have a TES -295 approval number and the Allison approval logo. Mobil Delvac Synthetic Automatic Transmission Fluid can be used or Allison TES -295 approved equals such as Castrol Transynd. Allison Transmission extended warranty plans require synthetic transmission fluids meeting the TES -295 specification with an approval number and the Allison approval logo to be used. The gearing shall be of the constant mesh, helical, planetary type with the following ratios: RANGE RATIO First 3.51:1 Second 1.91:1 Third 1.43:1 Fourth 1.00:1 Fifth 0.74:1 Sixth 0.64:1 Reverse 4.80:1 A function of the electronic controls shall be provided to prevent premature engagement and operation of the automatic transmission reverse gear. The transmission shall be governed by electronic controls, which contain a programmable read- only memory (PROM) that will provide basic transmission control functions. All cabling and electronic devices utilized by the electronic transmission control system shall be adequately shielded againstinterfercnce. The transmission electronic module shall be capable of communicating with the engine electronic module to maintain maximum efficiency. The control module shall be equipped with a self-diagnostic system. A failure shall be retained by the control module for evaluation by garage personnel using a Allison DOC software and J1939 / RS232 translation device. Modified diagnostics shall provide timely information on transmission oil and filter change requirements and transmission rebuild timeframes. The electronic controls shall be completely sealed from the environment. The transmission electronic control unit shall be located in a weatherproof box that is protected from environment or potential damage from under floor baggage. Page I of 21 SCAAN No.203744 Description : d4500_ISX12_EPA2013 425HP_373_TC541 Date: 1/30/2013 User: Alvaro Lazcano, MCIINAC Application Review Status Output Units : US ALLISON TRANSMISSION INPUT SUMMARY vwn i ivry $eNlne BITS Application Intercity Bus Configuration Siraighl Vehicle Vocation Number 44-25-14 VEHICLE PARAMETERS uescn non End User (and Region, Sub Region) Motor Coach Industries LTD (North America, Canadian) Manufacturer (and Region, Sub Region) Motor Coach Industries (North America, Canadian) Model D4500 com Description ID4500 Commuter .me ano rver ni Power Packs 1 Height 11.40 (ft) WAdth 8.50 (ft) Standard Wind Resistance Coefficient i No Deflector) 0.45 User Defined Resistance Coefficient ( No Deflector) 0.00 Weight. Rated ( No Trailer, GVW) 50000 (lb) Weight on Drive Wheels 42.00(%) Weight on Drive Wheels 21000 (Ib) I nes Number of Tires 8 Manufacturer ISX12 EPA13 Tire Model 8 Size 425hp 114501bft / 210 rpm Tire Type Standard Radial Tire Revs 490 (revs/mi) Radius 20.58 (m.) Standard Surface Factor 1.0 Smooth Concrete Use Defined Surface Factor 0.0 Standard Traction Limit Coefficient ( On -Road 1 0.70 uvmmo Engine Manufacturer Cummins Model ISX12 EPA13 Description 425hp 114501bft / 210 rpm Certification Year 2013 Peak Torque/Speed 1450.0/1100 (lb-ft)/(rpm) Peak PowerlSpeed 425.0/1800 (hp)/(rpm) Governed Power/Speed 397.8/2100 (hp)/(rpm) Cruise Velocity/Speed 65.0/1370 (mph)/(rpm) Vocation 0 Engine Curve Reference FR20402MC No, Of Curves Single SCAAN File Number 2-1307 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.a I I isontransm iss ion.com/extranet/iscaan/SCAANReports?f=Oct282013_ 144... 10/28/2013 Page 2 of 21 Power at ovemed s eed manufacturerV Standard (hp) User (hp) Fan (clutch fan) 57.36 65.00 Alt/Generator 8.50 12.00 Air Compressor 2.48 1.50 Steer Pump 2.48 1.50 Air Conditioning 0.00 22.00 manufacturerV Allison Configuration 8500 (1-6) (1-500-3) Converter TC541 (NOT RECOMMENDED - Smoke Control) (1-541-1) Retarder 303.7 Shift Calibration 2100 rpm S1/S5 Pert, Std Preselects, (1-6) (1-500-2100-1003) Rating Intercity Coach w/4th & 5th Gen Controls (1-500-4) c Propshaft DriveAxles Std Efficiency 98.60(%) Axle 6x2 On Hwy Single Red Manufacturer 303.7 Description 1284.4 Ratio Description Single Ratio 3.730 Std Efficiency 97.00(%) Overall Driveline 1309.3 Ratio 3.730 Std Efficiency 195.64(%) GRADES Std Acceleration lo.00m ENGINE DETAIL - Standard Accessories (AC On where applicable) LVW MIIV nl I Speed Power Torque (rpm) (hpl (Ib -ft) Fan On/AC On Net Power I (hp) Fan On/AC On Net Torque (lb -ft) Fan OH/AC On Net Power IIP) Fan Off/AC On Net Torque (Ib -ft) 1100 303.7 11450.0 1284.4 1357.8 292.6 1397.2 Peak Torque 1200 331.3 11450.0 1309.3 1353.7 320.0 1400.5 1300 358.9 11450.0 1333.8 1348.5 347.4 1403.4 1400 386.5 11450.0 1357.8 1342.1 374.8 1405.9 1500 414.1 11450.0 1381.2 1334.8 402.1 1408.0 1600 429.6 11410.0 392.0 11286.6 417.3 1369.8 1700 430.5 11330.0 387.6 1197.5 418.0 1291.5 1800 425.0 11240.0 376.2 1097.6 412.3 1202.9 Peak Power 1900 419.6 11160.G 364.31006.9 406.7 1124.2 2000 411.3 1080.0 348.6 915.4 398.1 1045.4 2100 397.8 995.0 327.1 818.1 384.4 961.5 Governed 2300 0.0 0.0 -89.2 -203.6 -13.9 -31.7 No Load Governed Peak Power point has been defined for the purposes of assessing Accessory Losses This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https:lliscaan.allisontransmission,cornlextranetliscaan(SCAANReports?f=OcO2013_144... [0/28/2013 Page 3 of 21 ENGINE DETAIL - User Defined Accessories (AC On where applicable) Low nna Speed (r 1 rn n rowe• Power Torque (hp) 1 (Ib -ft) Fan OnIAC On Net Power (hp) Fan OnIAC On Net Torque (Ib-ftl Fan Off/AC On Net Power (hpl Fan MAC On Net Torque hb-ftl 1100 303.7 11450.0 269.3 1285.6 278.6 1330.2 Peak Torque 1200 331.3 11450.0 292.9 1281.9 305.0 1335.0 1300 358.9 11450.0 316.0 1276.7 331.4 1339.0 1400 386.5 11450.0 338.6 1270.2 357.9 1342,5 1500 414.1 11450.0 360.6 1262.5 334.3 1345.5 1600 429.6 11410.0 369.8 1213.7 398.5 1308.1 1700 430.5 1330.0 363.8 1123.9 398.3 1230.4 1800 425.0 1240.0 350.6 1023.0 391.6 1142.5 Peak Power 1900 419.6 1160.0 336.9 931.2 385.0 1064.3 2000 411.3 1080.0 319.3 838.5 375.5 986.0 2100 397.8 995.0 295.8 739.9 360.8 902.5 Govemed 2300 0.0 0.0 -124.8 -284.9 .39.4 .89.9 No Load Govemed Peak Power point has been defined for the purposes of assessing Accessory Losses This SCAAN informabon is subject to the SCAAN Disclaimer set forth elsewhere. https:Hiscaan.a l l i sontransm iss ion.com/extranetliscaani SCAANReports?P-0ct2820 13_ 144... 10/28/2013 Page 4 of 21 SCAAN No.: 203744 Descnption:44500_ISX12_EPA2013_425HP_373_TC541 Date: 1/30/2013 User: Alvaro Lazcano, MCl/NAC Application Review Status . Output Units: US ALLISON TRANSMISSION SCAAN SUMMARY Based On Standard Parameters Vocation: Bus, Intercity Bus, Straight Vehicle End User: Motor Coach Industries LTD (North America. Canadian) Manufacturer: Motor Coach Industries (North America. Canadian) Model'. D4500 cmm. D4500 Commuter Engine: Cummins ISX12 EPA13 425hp 114501bft / 2100rpm Engine Certification Year. 2013 Transmission: B500 (1-6) Rating: Intercity Coach w/4th & 5th Gen Controls Converter: TC541 (NOT RECOMMENDED - Smoke Control) Retarder converter Check Check Name RecomMRating Unita Mini Max Actual Overall Status Ct Transmission/Convener Compatibility 35.5 Max V13 Status OK C2 Engine/Converter Compabbsily 4.039 V14 tat Range 80% Converter Efficiency Gradeability 16.0 OK OK C4 Engine Speed At Converter Stall V17 rpm mph 1628 T2 C9 Engine Speed At Converter Stall, Smoke Control 1825 m Min 1628 XX C5 Minimum Engine Speed 1200 m Min 1828 OK C7 Turbine Torque At Stall 2450 lb -ft Max 2347 OK C8 Converter Speed Ratio at 2100 m 0.800 Min 0.916 OK C3 Converter Stall Torque Ratio h Max 431 1.897 T14 r ransmrsson Check Check Name Recom ntRating Units Mini Actual Overall tat Range Converter Stall Gradeability vercent Actual 35.5 Max V13 Status Ti Transmission/VoceOon Compatibility 23.9 4.039 V14 tat Range 80% Converter Efficiency Gradeability 16.0 OK Min Transmission Compatible with High Torque Rise Diesel OK V17 Maximum Geared Vehicle Speed At Engine Governed Speed mph OK T2 Engines V18 Maximum Speed on 0.50% Grade 65.0mph Min 89.4 T20 orque Limiting: Engine & Transm SEM/LRTP Reqd Heat Generated in 1st Range 70% Converter Efficienq Btu/min 5259 OK V44 Transmission Permitted in End User/Chassis Mfg Btu/min 3684 OK T17 Locations T15 Input Power(Gross) 550 h Max 431 OK T14 Input Torque(Gmss) 1700 Ib -ft Max 1450 OK T3 input Speed (Engine Governed Speed) 1700/2300 rpm 1 2100 OK T4 Transmission Output Speed rpm 1 3286 venaaeru 0UM' Check Check Name Recomm/Rating Units Mini Max Actual Overall Status V21 tat Range Converter Stall Gradeability vercent Actual 35.5 V13 1st Range 70% Converter Efficiency Net Gradeability percent us Status 23.9 4.039 V14 tat Range 80% Converter Efficiency Gradeability 16.0 percent Min 20.5 OK V17 Maximum Geared Vehicle Speed At Engine Governed Speed mph 107.9 V18 Maximum Speed on 0.50% Grade 65.0mph Min 89.4 OK V43 Heat Generated in 1st Range 70% Converter Efficienq Btu/min 5259 V44 lHeat Generated in 1 st Range 80% Converter Efficiency Btu/min 3684 vehtcl&,V iveon&Fuei Economy Check Check Name RecommlRating Unite Mini Actual Ova Max us Status V51Maximum Driveline Ratio for Optimum Engine S 4.039 Max 3.730 OK V59 Gradeabil at 85.0 mph Cruise Velocity 0.50 percent I Min 2.65 OK https://iscaan.allisontransmission.comlextranetliscaanISCAANReports?f—�Oct282013_ 144... 10/28/2013 Page 5 of 21 at 2C-21- Shift 1 7.0 1 percent I Min 1 9.7 1 OK OK: Acceptable OK -1, OK based on pre -acceptance by Engineering OK -2: OK based on Accepted Application Review C: Consider- manufacturer to assess XX: Questionable - may not be acceptable XXX: Not Acceptable - rating or usage violation This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https:lliscaan.all isontransmission.cornlextranetliscaanISCAANReports?f-0ct2820l 3_144... 10/28/2013 Page 6 of 21 Notes Check Comments C5 (Net peak torque speed, allowable variation is 1100 + 100 rpm) T4 Range 61- at 2100 rpm Engine Governed Speed V17 In 6 Lockup V18 At 2008 rpm Engine Speed. Range 5L V43 At 1759 rpm Engine Speed V44 At 1806 rpm Engine Speed V51 Recommended Raeo based on 6L operation at Cruise Conditions of 65.0 mph at 1370 rpm. Actual Ratio results in 65.0 mph at 1265 rpm. (Engine mfg recommendation is 65.0 mph at 1370 rpm). V60A Actual Gradeabifity in 21 V61 lRecommended 51--61L Shift Speed is Cruise Speed - 5.0 mph This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.all isontransm ission.com/extranet/iscaan/SCAANReports?f=Oct282O l 3_ 144... 10/28/2013 Page 7 of 21 SCAAN No. :203744 Description: d4500_ISX12_EPA2013_425HP_373_TC541 Date, 1/30/2013 User: Alvaro Lazcano, MCINAC Application Review Status Output Units : US ALLISON TRANSMISSION SCAAN SUMMARY Based On User Defined Parameters Vocation. Bus, Intercity Bus, Straight Vehicle End User: Motor Coach Industries LTD (North America, Canadian) Manufacturer: Motor Coach Industries (North America, Canadian) Model: D4500 com, D4500 Commuter Engine: Cummins ISX12 EPA13 425hp 114501bft 12100rpm Engine Certification Year: 2013 Transmission: B500 (1-6) Rating: Intercity Coach w/41h & 5th Gen Controls Converter: TC541(NOT RECOMMENDED - Smoke Control) Retarder. VGIlvilevV1lvGUG Check Check Name Recomm/Rating Units Minl Max Actual V21 1 st Range Converter Stall Gradeabiliry percent 4.039 34.0 V13 1st Range 70% Converter Efficiency Net Gradeabliily percent Gradeability at 65.0 mph Cruise Velocity 23.0 V14 1st Range 80% Converter Efficiency Gradeabiliry 18.0 percent Min 19.7 V17 Maximum Geared Vehicle Speed At Engine Governed Speed mph 9.1 107.9 V18 Maximum Speed on 0.50% Grade 65.0 mph Min 87.5 V43 Heal Generated in tat Range 70% Converter Efficiency Btu/min 5187 V44 I Heat Generated in 1st Range 80% Converter Efficiency Btu/min 1 1 3632 venxaerunve"I". l cw•w• Check Check Name Recomm/Rating Units Min/ Max Actual V61 12aximurn Driveline Ratio for Optimum Engine Speed 4.039 Max 3.730 V59 Gradeability at 65.0 mph Cruise Velocity 0.50 percentMin 2.40 V60A Gradeabiliry al2C-2L Shift 7.0 percent Min 9.1 V61 Vehicle Speed at 5L -6L Shift 60.0 mph Max 91.3 OK: Acceptable OK -1 OK based on pre -acceptance by Engineering OK -2: OK based on Accepted Application Review C: Consider- manufacturerto assess XX: Questionable - may not be acceptable XXX: Not Acceptable - rating or usage violation This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan. al I isontransmission.com/extranet/iscaan/SCAANReports?f=Oct2820 13_ 144... 10/28/2013 Pagc 8 of 2I ,voles Check Comments V17 In 6 Lockup V18 At 1966 rpm Engine Speed, Range 5L V43 At 1761 rpm Engine Speed V44 At 1797 rpm Engine Speed V51 Recommended Ratio based on 6L operation at Cruise Conditions of 65.0 mph at 1370 rpm. Actual Ratio results in 65.0 mph at 1265 rpm. (Engine mfg recommendation is 65.0 mph at 1370 rpm). V60A Actual Gradeabiliry in 2L V61 Recommended 5L -6L Shift Speed is Cruise Speed - 5.0 mpt, This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https:Hiscaan.al lisontransm ission.comlextranet/iscaanISCAANReport's?f-0ct2820l3_144... 10/28/2013 Page 9 of 21 SCAAN No.: 203744 Description: d4500 ISX12_EPA2013_425HP_373_TC541 Date : 1130/2013 User. Alvaro Lazcano, MCl/NAC Application Review Status: Output Units: US ALLISON TRANSMISSION CUSTOMER PERFORMANCE SUMMARY Based on Standard Parameters Vocation: Bus, Intercity Bus, Straight Vehicle End User: Motor Coach Industries LTD (North America, Canadian) Manufacturer: Motor Coach Industries (North America. Canadian) Model: D4500 com, D4500 Commuter Engine: Cummins ISX12 EPA13 425hp / 145011oft 12100rpm Engine Certification Year: 2013 Transmission: 8500 (1-6) Rating: Intercity Coach w/4th 8 5th Gen Controls Converter: TC541 (NOT RECOMMENDED - Smoke Control) Retarder Weight: 50000 (lb) (GVV4) Driveline Ratio: 3.730 Tires: Standard Radial Tire, 490.0 (revs/ ml) Geared Speed. 107.9 (mph) 61- Clutch L Clutch Fan Status : Fan On Air Conditioning Status : No AC oraueawm Launch Gradeabilil 33.5(%) Low Speed Gradeability 20.5(%) at 10.1(mph), 80(%) Conv E8 Grade Maximum Speed On Grade MAO(%) at 93.3(mph), 6L, Road Load Speed 0-50 (mph) 0.25(%) at 88.0(mph), 51- L0.50(%) 0.60 (mph) 0.50(%)at 85.6(m h). 5L 1.00(%) at 80.7(mph), 5L 2.00(%) at 70.6(mph), 5L 3.00(%) at 59.1 (mph), 4L 4.00(%) at 52.2(mph). 4L 5.00(%) at 42.6(mph), 3L 6.00(%) at 39.4(mph), 3L 7.00(%) at 32.4(mph). 2L 8.00(%) a[ 31.2(mph), 2L 9.00(%) at 28.0(mph), 2L 10.00(%) at 202(m ), 2C nccvrc.auw, ,mnmm�e. v Time And Distance To Speed. 0(%) Grade 0-20 (mph) in 5.5(sec) 98(ft) 0-30 (mph)in 10.8(sec) 293(ft) 0-40 (mph) in 18.0(sec) 666(ft) 0-50 (mph) lin 28.4(sec) 1352(ft) 0.60 (mph) lin 41.6(sec) 2431(ft) This SCAAN Information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.allisontransmission.com/extranetliscaanISCAANReports?f-0ct282013_ 144... 10/28/2013 Page 10 of 21 SCAAN No.: 203744 Description: d4500_ISX12 EPA2013_425HP_373_TC541 Date: 1/30/2013 User: Alvaro Lazcanc, MCI/NAC Application Review Status: Output Units: US ALLISON TRANSMISSION CUSTOMER PERFORMANCE SUMMARY Based on User Defined Parameters Vocation: Bus, Intercity Bus, Straight Vehicle End User: Motor Coach Industries LTD (North America, Canadian) Manufacturer: Motor Coach Industries (North America, Canadian) Model: D4500 com. D4500 Commuter Engine: Cummins ISX12 EPA13 425hp / 14501bft / 2100rpm Engine Certification Year 2013 Transmission: B500 (1-6) Rating: Intercity Coach w/4th & 5th Gen Controls Converter: TC541 (NOT RECOMMENDED - Smoke Control) Retarder: Weight: 50000 (lb) (GVW) Driveline Ratio: 3.730 Tires: Standard Radial Tire, 490.0 (reVa%ml) Geared Speed: 107.9 (mph) 6L Clutch Fan Status : Fan On Air Conditioning Status : On ura0eamu Launch Gradeability 32.0(%) Low Speed Gradeabdity 19.7(%) at 9.9(mph), 80(%) Conv Eft Grade Maximum Speed On Grade 0.00(%) at 88.2(mph), 5L, Road Load Speed 0-50 (mph) 0.25(%) at 85.8(mph), 5L 0-60 (mph) 0.50(%) at 83.4(ni 51 1.00(%) at 78.6(mph), 5L 2.00(%) at 67.3(mph), 5L 3.00(%) at 57.2(mph), 4L 4.00(%) at 47.7(mph), 4L 5.00(%) at 41.0(mph), 3L 6.00(%) at 37-4(m h), 3L 7.00(%) at 31.8(mph), 2L 8.00(%) at 29.6(mph), 2L 9.00(%) at 24.9(mph), 2L 10.00(%) at 18.8(mph). 2C Hccererenon run rnrama, uwnea ,wpm. am.. Time And Distance To Speed. 0(%) Grade 0-20 (mph) lin 5.6 sec 103011) 0-30 (mph) in 11.4(sec) 312(ft) 0-40 (mph) lin 19.2(sec) 714(ft) 0-50 (mph) Jim 30.5(Sec) 1462(ft) 0-60 (mph) lin 45.1 (see) 2646(ft) This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.allisontransmission.comlextranet/iscaanISCAANReports?f=0ct282013_ 144... 10/28/2013 SCAAN No.: 203744 Descnption: d4500_ISx12_EPA2013_425HP_373_TC541 Date: 1/30/2013 User: Alvaro Lazcano, MCI/NAC Application Review Status: Output Units : US ALLISON TRANSMISSION VEHICLE FULL THROTTLE PERFORMANCE Based on Standard Parameters Transmission Input Ratio: 1.0000 Transmission Input Efficiency (%): 100.00 Clutch Fan Status : Fan On Air Conditioning Status: No AC Azle Ratio: 3.730 Auxiliary Gearing Ratio: 1.000 Power Packs. i Page I I of 21 A tomatrc 1C -2C -2L -3L -4L -5L -6L u Vehicle Speed (mph) Engine Speed (rpm) Tractive Effort (lb) Drawbar Pull (lb) Wheel Power (hp) Net% Grade I%) Transm Heat Rel (Btu/min) RIC 0.0 1628 22626 22414 0.0 50.1 16575 RIC 4.0 1719 17802 17579 189.9 37.6 7927 R1C 5.7 1759 15904 15674 241.0 33.0 5466 70Percent RIC 7.4 1806 13789 13553 270.4 28.2 3934 BOPercenl R1C 8.0 1825 13006 12768 277.5 26.4 3525 80Percent R1C 8.7 1841 12279 12037 284.0 24.8 3154 85Percent R'C 12.0 1973 8614 8357 275.7 17.0 2740 RIC 13.2 2100 7531 7269 264.2 14.7 2157 Governed RIC 15.3 2253 0 .2741 0.01 45 692 A tomatrc 1C -2C -2L -3L -4L -5L -6L u Vehicle Speed (mph) I Engine Speed (rpm) Tractive Effort (Ib) Drawbar Pull (lb) Wheel Power (hp) Not% Grade %) Transco Heat Re( (Btulmin) 1C 0.01 1628 16955 16743 0.0 35.5 16575 1C 4.0 1690 14162 13939 151.1 29.0 9761 Ic 7.8 1759 11874 11637 246.1 23.9 5239 70Percent IC 8.0 1763 11718 11479 250,0 23.6 5048 1C 10.1 1806 10295 10047 276.1 20.5 3680 80Percent 1C 11.9 1841 9164 8908 289.9 18.1 2893 85Percent 1C 12.0 1843 9084 8827 290.7 17.9 2848 1C 14.7 1909 7454 7183 293.0 14.5 2396 2C 14.7 1763 6376 6105 250.61 12.3 5019 2C 16.0 1777 6116 5836 261.01 11.8 4494 2C 20.0 1823 5309 5006 283.2 10.1 3280 2C 24.0 1867 4594 4263 294.0 8.6 2576 2C 24.2 1871 4552 4219 294.1 8.5 2557 2L 24.2 1407 5149 4816 332.7 9.7 488 2L 28.0 1626 411401 4477 361.4 9.0 552 2L 32.0 1858 3974 3576 339.1 7.2 624 2L 34.0 1975 3549 3133 321.9 6.3 677 3L 34.0 1480 3850 3434 349.2 6.9 487 31 36.0 1567 3750 3314 360.01 6,6 510 31 40.0 1741 3317 2840 353.9 5.7 549 3L 44.0 1915 2832 2310 332.3 4.6 611 31 46.0 2000 2600 2054 318.7 4.1 649 41 46.0 1400 2721 2175 333.5 4.4 384 41 48.0 1462 2715 2144 347.5 4.3 381 4L 52.0 1584 2628 2005 364.4 4.0 392 P4L 56.0 1708 2415 1737 360.6 3.5 421 4L 60.0 18281 21651 1429 346.4 2.9 4551 1 https:Hiscaan.aIlisontransm ission.com/extranet/iscaan/SCAANReports?f=Oct282013_144... 10/28/2013 Page 12 of 21 4LI M. 64.01 1950 19321 1135 329.81 2.3 495 4LI 66.51 2025 17841 947 316.31 1.9 529 5L 66.5 1493 1972 1135 349.6 2.3 593 5L 68.0 1527 1951 1089 353.8 2.2 602 5L 72.0 1617 1874 944 359.8 1.9 637 5L 76.0 1706 1751 749 354.8 1.5 674 5L 80.0 1796 1614 537 344.2 1.1 707 5L 84.0 1886 1488 333 333.4 0.7 737 5L 88.0 1976 1362 125 319.6 0.3 770 5L 91.3 2050 1253 -53 305.2 -0.1 798 6LI 91.31 1777 14011 95 341.21 0.2 937 6LI 92.01 1791 13831 61 339.3 0.1 953 6Lf G6.01 1869 1287 -123 329.4 -0.2 999 6L 100.01 1946 1191 -310 317,6 -0.6 1055 6L 104.0 2024 1093 -503 303.2 -1.0 1118 6L 107.9 2100 994 -698 286.0 -1.4 1193 Governed 6L 108.0 2102 979 -716 282.0 -1.4 1193 6L 112.0 2180 453 -1343 135.3 -2.7 1206 6L 115.4 2247 0 -1886 0.0 -3.81 1215 Note : ' Tractive Effort exceeds vehicle traction limit (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 Note: Requested AC On Report is not included because AC Loss is 0.0 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al I isontransmission,coin/extranet/iscaan/SCAANReports?f=Oct282013_144... 10/28/2013 VehicleV Speed (mph) I Engine Speed (rpm) Tractive Effort (lb) Drawbar Pull (lb) Wheel Power (hp) Net% Grade (%) Transm Heat Re] (etulmin) 1C 0.01 1628 16955 16743 0.0 35.5 16575 ' 1C 4.0 1690 14162 13939 151.1 29.0 9761 1C 7.8 1759 11874 11637 246.1 23.9 5239 1 70Percent 1C 8.0 1763 11718 11479 250.0 23,5 5048 1C 10.1 1806 10295 10047 276.1 20.5 3680 80Percent 1 C 11.9 1841 9164 8908 289.91 18.1 2893 85Percent 1C 12.0 1843 9084 8827 290.71 17.9 2848 1C 12.8 1860 8609 16.9 2652 1L 12.8 1365 9480 _14929121 9220 322.8 18.8 506 1L 16.01 1 8323 8045 355.11 16.3 639 1L 19.6 2100 5631 5330 294.9[A 796 Governed 1 L 20.0 2139 4209 3906 224.5 778 1L 21.1 2252 0 -310 0.0 715 Note : ' Tractive Effort exceeds vehicle traction limit (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 Note: Requested AC On Report is not included because AC Loss is 0.0 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al I isontransmission,coin/extranet/iscaan/SCAANReports?f=Oct282013_144... 10/28/2013 SCAAN No.: 203744 Description: d4500_ISX12_EPA2013_425HP_373_TC541 Date: V30/2013 User: Alvaro Lazcano, MCl/NAC Application Review Status: Output Units: US ALLISON TRANSMISSION VEHICLE FULL THROTTLE PERFORMANCE Based on User Defined Parameters Transmission Input Ratio : 1.0000 Transmission Input Efficiency (%): 100.00 Clutch Fan Status: Fan On Air Conditioning Status: OR Axle Ratio: 3.730 Auxiliary Gearing Ratio: 1.000 Power Packs:1 Page 13 of 21 P Vehicle Speed (mph) I Engine Speed (rpm) Tractive Effort (lb) Drawbar Pull Iib) Wheel Power (hp) Net% Grade N Transm, Heat Raj (Btu/min) RIC 0.0 1621 22422 22210 0.0 49.6 16353 ' RIC 4.0 1711 17622 17399 188.0 37.1 7791 ' RIC 5.7 1751 15751 15522 237.6 32.7 5390 70Percent RIC 7.3 1797 13650 13414 266.3 27.8 3878 80Percent RIC 8.0 1815 12823 12584 273.5 26.0 3458 80Percent RIC 8.6 1831 12150 11909 279.5 24.5 3109 85Percent RIC 12.0 1968 44 87 8190 270.3 16.6 2670 RIC 13.2 2100 7309 7G461 257.21 14.2 2077 Govelnetl RICI 15.21 2248 01_ -2741 0.0 -0.5 686 P Vehicle" Speed (mph) Engine Speed (rpm) Tractive Effort jib) I Drawbar Pull (ib) Wheel Power (hp) Net% Grade (%) Transm Heat Rej (Btu/min) 1C 0.0 1621 168021 16590 0.01 35.2 16353 ' IC 4.0 1683 140181 13795 149.5 28.7 9591 1C 7.7 1751 117601 11522 242.6 23.7 5166 70Percenl 1C 8.0 1756 115781 11339 247.0 23.3 4946 1C 10.0 1797 101901 9943 271.9 20.3 3629 80Percent 1C 11.8 1831 90671 6812 285.3 17.9 2852 85Percent 1C 12.0 1834 8950 8693 286.4 17.7 2787 1 C 14.7 1901 7322 7051 287.8 14.2 2365 2C 14.7 1756 6300 6029 247.6 12.1 4917 2C 16.0 1769 6040 5762 257.71 11.6 4400 2C 20.0 1814 5234 4931 279.21 9.9 3217 2C 24.0 1859 4519 4187 289.21 8.4 2527 2C 24.2 1862 4479 4146 289.41 6.3 2504 21. 24.2 1407 5083 4750 328.41 9.5 487 2L 28.0 1626 4768 4405 356.0 8.8 550 2L 32.0 1858 3894 3496 332.3 7.0 622 2L 34.0 1975 3465 3048 314.2 6.1 674 3L 34.0 1480 3800 3383 344.6 6.8 485 3L 36.0 1567 3697 3261 355.0 6.5 509 3L 40.0 1741 3261 2784 347.9 5.6 547 31- 44.0 1915 2771 2248 325.1 4.5 609 31- 46.0 2000 2536 1990 310.8 4.0 647 41. 46.0 1400 26861 21401 329.21 4.3 384 4L 48.0 1462 2679 2109 343.0 4.2 381 4L 52.0 1584 2591 1968 359.3 3.9 392 4L 56.0 1706 37 26 16981 354.81 3.4 421 4L 60.01 1828 21241 13881 339.81 2.8 454 https://iscaan.alIisontransm ission.com/extranet/iscaan/SCAANReports?f=Oct282013_144... 10/28/2013 Page 14 of 21 4L 64.01 1950 latial 1091 322.21 2.2 495 11 4L 66.5 2025 17381 901 308.21 1.8 528 SL 66.5 1493 19461 1109 344,91 2.2 592 5L 68.0 1527 1925 1062 349.01 2.1 600 5L 72.0 1617 1847 916 354.6 1.8 635 5L 76.0 1706 1722 720 349.1 1.4 672 5L 80.0 1796 1584 507 337.9 1.0 705 5L 84.0 1886 1457 302 326.4 0.6 734 SL 88.0 1976 1329 93 311.9 0.2 767 5L 91.3 2050 1219 -87 296.8 -0.2 795 6L 91.3 1777 1376 69 335.0 0.1 935 6L 92.0 1791 13571 36 333.0 0.1 951 6L 96.0 1869 1260 -150 322.6 -0.3 996 6L 100.0 1946 1163 -338 310.2 -0.7 1051 6L 104.0 2024 1064 -532 295.1 -1.1 1115 6L 107.9 2100 963 -728 277.2 -1.5 1189 Governed 6L 108.0 2102 948 -746 273.1 -1.5 1190 6L 112.0 2180 421 -1375 125.7 -2.8 1202 GLI 115.21 2242 0 -1880 0.0 -3.8 1210 1 tLocku Hold 1C -1L s Vehicle Speed (mph) Engine Speed (rpm) Tractive Effort (lb) Drawbar Pull (lb) Wheel Power (hp) Net % Grade (%) Transm Heat Raj (Btu/min) 1C 0.0 1621 16802 16590 0.0 35.2 16353 ' 1C 4.0 1683 14018 13795 149.5 28.7 9591 1C 7.7 1751 11760 11522 242.6 23.7 5156 70Percent 1C 8.0 1756 11578 11339 247.0 23.3 4946 80Percent 1C 10.0 1797 10190 9943 271.9 20.3 3629 80Percent ICI 11.8 1831 90671 8812 267.4 17.8 2852 85Percent 1 C 12.0 1834 8950 8693 257 4 17.7 2787 1C US 1852 8472 8211 240.3 16.6 2599 Governed 1L 12.8 1365 9358 9098 0.0 18.5 504 1L 16.0 1711 8188 7910 ]86.1 16.0 fi36 1L 19.6 2100 5463 5163 10A 792 Governed 1L 20.0 2139 4038 3734 7.5 774 IL 21.0 2248 0 -310 -0.6 713 Clutch Fan Status : Fan On Air Conditioning Status : On Axle Ratio: 3.730 Auxiliary Gearing Ratio. 1.000 Vehicle I Engine I Tractive ( Drawbar Wheel Wheel j Net% Transm Speed Speed Effort Pull Power I Grade Heat Raj https://iscaan.al I isontransm ission.com/extranet/iscaan/SCAANReports?f=Oct282013_ 144... 10/28/2013 Vehicle Speed (mph) Engine Speed (rpm) Tractive Effort (lb) Drawbar Pull (Ib) Wheel Power Ihp) Net % Grade (%) Transm Heat Re B[u/min) RIC 0.0 1596 217871 21575 0.0 47.8 15671 RIC 4.0 1689 17061 16837 182.0 35.8 7388 '. Ric 5.6 1726 15320 15091 227.8 31.7 5181 70Percent Ric 7.2 1772 13258 13023 255.2 27.0 3711 80Percent Ric 8.0 1793 12326 12088 263.0 24.9 3251 R12 8.5 1803 11802 11561 267.4 23.8 2995 85Percent R1C 12.0 1958 8045 7789 257 4 15.8 2443 RlC 13.3 2100 6780 6517 240.3 13.1 1893 Governed RIC 15.1 2237 0 -273 0.0 -0.5 684 Vehicle I Engine I Tractive ( Drawbar Wheel Wheel j Net% Transm Speed Speed Effort Pull Power I Grade Heat Raj https://iscaan.al I isontransm ission.com/extranet/iscaan/SCAANReports?f=Oct282013_ 144... 10/28/2013 Page 15 of21 1st LocrzUD (Mph) I (rpm) (lb) I Ob) (hpl I em (stulminl 1C 1C 0.01 1596 163271 16115 0.0 34.0 15671 ' 4.0 1C 4.0j 1660 135801 13357 144.91 27.7 9107 1726 1C 7.6 1726 114371 11200 232.61 23.0 4968 70Percen 1C 8.0 1733 111801 10942 238.5 22.4 4666 9650 1C 9.9 1772 98971 9650 260.5 19.7 3474 BOPercent 1C 11.6 1803 8807 8552 272.9 17.4 2751 85Percent 1C 12.0 1810 8583 8326 274.7 16.9 2634 1 C 14.7 1879 6972 6701 274.0 13.5 2261 2C 14.7 1734 6084 5812 239.1 11.7 4639 2CI 16.0 1747 5826 5547 248.6 11.2 4142 2CI 20.01 1791 5031 4728 268.3 9.5 3021 2C 24.01 1836 4322 3991 276.6 8.0 2392 2C 24.2 1839 4284 3951 276.8 7.9 2369 2L 24.2 1407 4866 4533 314.4 9.1 481 2L 28.0 1626 4552 4189 339.9 8.4 544 2L 32.0 1858 3678 3280 313.8 6.6 615 2L 34.0 1975 3248 2831 294.6 5.7 667 3L 34.0 1480 3637 3220 329.9 6.5 481 3L 36.0 1567 3535 3099 339.4 6.2 505 3L 40.0 1741 3099 i 2621 330.5 5.2 543 11 31-1 44.0 1915 2608 2086 306.D 4.2 604 3L 46.0 2000 23731 1827 290.8 3.7 642 4Lj 46.0 1400 25721 2026 315.2 4.1 384 41-1 48.0 1462 25651 1994 328.3 4.0 381 41.1 52.0 1584 24761 1854 343.4 3.7 392 41-1 56.0 1706 22611 1584 337.7 3.2 421 41-1 60.0 1828 20091 1273 321.5 2.5 454 4LI 64.0 1950 17741 977 302.7 2.0 495 41-1 M51 2025 16241 787 287.9 1.6 528 5L 66.51 1493 1862 1025 330.1 2.1 587 5LF 68.01 1527 1841 979 333.8 2.0 595 5L 72.0 1617 1763 833 338.5 1.7 630 51. 76.0 1706 1639 637 332.11 1.3 666 51, 80.0 1796 1500 423 320.11 0.8 6991 1 5L 84.0 1886 1373 218 307.61 0.4 7281 1 5L 88.0 1976 1246 9 292.31 0.0 760 5L 91.3 2050 1135 -171 276.4 -0.3 788 61. 91.3 1777 1303 -3 317.3 -0.0 928 6L 92.0 1791 1285 -37 315.2 -0.1 944 6L 96.01 1869 1188 -222 304.0 -0.4 989 6L 100.0 1946 1091 -411 290.9 -0.8 1044 6L 104.0 2024 991 -605 275.0 -1.2 1107 6L 107.9 2100 891 -801 256.3 -1.6 1181 Governed 6L 108.0 2102 876 -8191 252.3 1.6 421 1181 6L 112.0 2180 349 -1448 104.1 -2.9 1194 6L 114.6 2231 0 -1 865 0 0[__ -3.71 12001 1 1st LocrzUD nwo 1 11 -IL Vehicle Speed (mph) Engine Speed (rpm) Tractive Effort (Ib) Drawbar Pull (lb) Wheel Power (hp) Net % Grade M Transm Heat Rej (Btulmin) 1C 0.0 1596 16327 16115 0.0 34.0 15671 ' 1C 4.0 1660 13560 13357 144.9 27.7 9107 1C 7.6 1726 11437 11200 232.6 23.0 4968 70Percent 1C 8.0 1733 11180 10942 238.5 22.4 4666 10 9.9 1772 9897 9650 250,5 19.7 3474 8OPercent https: //iscaan.a I I isontransm ission.com/extranetliscaan/SC AANReports?f=Oct282013_ 144... 10/28/2013 Page 16 of 21 1C 11.61 1803 88071 8552 272.91 17.4 2751 85Percen I 12.0 1810 86831 8326 274.71 16.9 2634 1C 12.8 1830 8100 7839 275.8 15.9 2468 1L 12.6 1365 8961 8700 3052 17.7 498 1 L 16.0 1711 7791 7512 332.4 15.2 628 1L 19.6 2100 5066 4765 265.3 9.6 782 Governed 1 L 20.0 2139 3640 3337 194.1 6.7 764 ILI 20.9 2237 0 -309 0.0 -0.6 709 Note :' Tractive Effort exceeds vehicle traction limit (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.aII isontransm ission.com/extranet/iscaan/SCAANReports?f--Oct282013_ 144... 10/28/2013 SCAAN No,: 203744 Description: d4500_ISX12_EPA2013_425HP_373 TC541 Date: 1/30/2013 User: Alvaro Lazcano, MCl/NAC Application Review Status Output Units: US Transmission Input Ratio : 1.0000 Transmission Input Efficiency (%): 100.00 Clutch Fan Status : Fan On Air Conditioning Status : No AC Grade: 0.0 percent Re- 1pfri ALLISON TRANSMISSION VEHICLE ACCELERATION PERFORMANCE Brakes Locked Start Based on Standard Parameters Axle Ratio: 3.730 Auxiliary Gearing Ratio: 1.000 Power Packs: 1 Page 17 of 21 '1(]9!":91 _11.11 _51 fit 1 Vehicle Speed Time (mph) (sec( Accel Distance Rate Ift) (mphtsec) Engine Speed (rpm) ERF 4.0 0.5 1.6 6.968 1719 8.0 1.2 7.6 5.038 1825 0.6 12.0 2.2 22.5 3.027 1973 '1(]9!":91 _11.11 _51 fit 1 Vehicle Speed I Time Distance AccelI Engine Rate Speed https://iscaan.al I isontransmiss ion.com/extranetliscaan/SCAANReports?f=0ct2820 13_ 144... 10/28/2013 Vehicle Speed (mph) Time (sec) Distance (ft) Accel Rate (mph/sec) Engine Speed (rpm) 1C 4.0 0.6 1.9 5.678 1690 1C 8.0 1.4 8.8 4.683 1763 iC 12.0 2.4 23.3 3.615 1843 1C 14.7 3.2 40.1 2.903 1909 2C 16.0 3.7 51.3 2.481 1777 2CI 20.0 5.5 97.5 2.128 1823 2C 24.0 7.5 163.5 1.806 1867 2C 24.2 7.7 167.9 1.789 1871 2L 28.0 9.6 243.0 1.839 1626 2L 32.0 12.0 350.3 1.470 1858 2L 34.0 13.5 420.9 1.290 1974 3L 36.0 14.9 493.5 1.389 1567 3L 40.0 18.0 666.0 1.192 1741 31 44.0 21.7 896.2 0.970 1915 31 46.0 23.9 1038.0 0.862 2000 4L 46.0 26.1 1191.4 0.910 1462 4L 52.0 30.6 1523.0 0.852 1584 4L 56.0 35.7 1921.7 0.739 1706 41- 60.0 41.6 2430.8 0.608 1828 4L 64.0 49.0 3102.9 0.484 1950 4L 66.5 54.6 3640.5 0.404 2025 5L 68.0 57.8 3956.2 0.466 1527 5L 72.0 67.0 4899.7 0.405 1617 5L 76.0 78.1 6105.6 0.321 17061 1 5L 80.0 92.8 7788.4 0.231 17961 1 5L 84.0 114.7 10430.4 0.144 1886 5L 88.0 158.7 15995.4 0.055 1976 Vehicle Speed I Time Distance AccelI Engine Rate Speed https://iscaan.al I isontransmiss ion.com/extranetliscaan/SCAANReports?f=0ct2820 13_ 144... 10/28/2013 Page 18 of 21 Note: ' Indicates acceleration limited by wheel slip (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 Note: Requested AC On Report is not included because AC Loss is 0.0 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al I isontransm ission.com/extranet/i scaan/SC A ANReports?1=Oct2820l 3_ 144... 10/28/2013 (mph) (sec) (h) (mph/see) (rpm) 1C 4.0 0.6 1.9 5.678 1690 1C 8.0 1.4 8.8 4.683 1763 1C 12.0 2.4 23.3 3.615 1843 1C 12,8 2.6 27.3 3.365 1860 1 L 16.0 3.6 48.5 2.951 1711 1 L 20.0 5.3 94.6 1.514 2139 Note: ' Indicates acceleration limited by wheel slip (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 Note: Requested AC On Report is not included because AC Loss is 0.0 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al I isontransm ission.com/extranet/i scaan/SC A ANReports?1=Oct2820l 3_ 144... 10/28/2013 SCAAN No.: 203744 Description .d4500_ISX12_EPA2013_425HP_373_TC541 Date: 1130/2013 User: Alvaro Lazcano, MCI/NAC Application Review Status Output Units : US Transmission Input Ratio: 1.0000 Transmission Input Efficiency (%): 100.00 Clutch Fan Status : Fan On Air Conditioning Status : Off Grade: 0.0 percent oe.,e...a ioeri ALLISON TRANSMISSION VEHICLE ACCELERATION PERFORMANCE Brakes Locked Start Based on User Defined Parameters Axle Ratio: 3.730 Auxiliary Gearing Ratio: 1.000 Power Packs: 1 Page 19 of 21 Vehicle Speed I Time Distance Accel Engine Rate I Speed https://iscaan.aiIisontransmission.com/extranet/iscaan/SCAANReports?f=Oct282013_ 144... 10/28/2013 Vehicle Speed Time Distance (mph) (sec( (h) Accel Rate Imphisec) Engine Speed (rp-) R1C 4.0 0,5 1.6 6.898 1711 R1C 8.01.2 7.7 4.971 1815 R1C 12.0 2.2 22.9 2.888 1968 Vehicle Speed I Time Distance Accel Engine Rate I Speed https://iscaan.aiIisontransmission.com/extranet/iscaan/SCAANReports?f=Oct282013_ 144... 10/28/2013 v Vehicle Speed (mph) Time (sec) Distance (ft) Accel Rate (mph/sec) Engine Speed (rpm) 1C 4.0 0.7 2.0 5.620 1683 1 C 8.0 1.4 8.9 4.626 1756 1 C 12.0 2.4 23.6 3.557 1834 1 C 14.7 3.3 40.7 2.851 1901 2C 16.0 3.8 52.0 2.448 1769 2C 20.0 5.61 98.9 2.097 1814 2C 24.0 7.61 165.9 1.775 1859 2C 24.2 7.8 170.5 1.759 1862 2L 28.0 9.8 246.6 1.810 1626 2L 32.0 12.2 356.1 1.438 1858 21 34.0 13.7 428.4 1.255 1974 3L 36.0 15.2 502.1 1.367 1567 3L 40.0 18.3 677.7 1.169 1741 3L 44.0 22.1 913.4 0.945 1915 3L 46.0 24.3 1059.4 0.835 2000 41 48.0 26.6 1215.4 0.895 1462 4L 52.0 31,2 1552.9 0.836 1584 4L 56.0 36.3 1959.8 0.723 1706 4L 60.0 42.5 2482.2 0.591 1828 41- 64,0 50.1 3177.8 0.465 1950 41 66.5 56.0 3740.0 0.384 2025 5L 68.0 59.3 4063.3 0455 1527 5L 72.01 68.7 5032.5 0.393 1617 5L 76.0 80.2 6280.0 0.309 1706 5L 80.0 95.6 8044.5 0.218 1796 5L 84.0 119.21 10895.3 0.130 1886 5L 88.01 172.01 17577.7 0.041 1976 Vehicle Speed I Time Distance Accel Engine Rate I Speed https://iscaan.aiIisontransmission.com/extranet/iscaan/SCAANReports?f=Oct282013_ 144... 10/28/2013 Page 20 of 21 Clutch Fan Status : Fan On Axle Ratio: 3.730 Air Conditioning Status On Auxiliary Gearing Ratio: 1.000 Grade: 0.0 percent Re„e�- Faari (mph) (sec) (R) (mph/sec) (rpm) 1C 4.0 0.7 2.0 5.620 1683 1C 8.0 1.4 8.9 4.626 1756 1C 12.0 2.4 23.6 3.557 1834 1C 12.8 2.7 27.7 3.306 1852 1 L 16.0 3.7 49.2 2.902 1711 1 L 20.0 5.4 96.5 1 452 2139 Clutch Fan Status : Fan On Axle Ratio: 3.730 Air Conditioning Status On Auxiliary Gearing Ratio: 1.000 Grade: 0.0 percent Re„e�- Faari 7WLOCKu Vehicle Speed Time Distance (mph) (sec) Ift) Accel Engine Rate Speed mph/sac) (rpm) R1C 4.0 0.5 1.6 6.684 1689 R1C 8.0 1.2 8.0 4.801 1793 R1C 12.0 2.3 24.1 2.669 1958 7WLOCKu Vehicle Speed (mph( Engine Speed (rpm) Time (sec) Distance (ft) Accel Rate (mph/sec) 1C Engine Speed Irpm) 1733 1 C 4.0 0.7 2.0 5.438 1660 1C 8.0 1.5 9.2 4.462 1733 1C 12.0 2.5 24.5 3.395 1810 1C 14.7 3.4 42.4 2.709 1879 2C 16.0 3.9 54.2 2.357 1747 2C 20.0 5.8 103.0 2.012 1791 2C 24.0 8.0 173.1 1.694 1836 2C 24.2 8.1 177.9 1.676 1839 2L 28.0 10.2 257.7 1.721 1626 2L 32.0 12.8 373.6 1.349 1858 2L 34.0 14.4 451.1 1.166 1974 3L 36.0 15.9 528.6 1.299 1567 3L 40.0 19.2 714.2 1,101 1741 31, 44.01 23.3 966.3 0.876 1915 3L 46.0 25.7 1124.5 0.767 2000 4L 48.0 28.1 1289.4 0.846 1462 4L 52.0 33.0 1646.8 0.788 1564 4L 56.0 38.5 2080.9 0.674 1706 4L 60.0 45.1 2645.6 0.542 1828 4L 64.0 53.5 3412.8 0.416 1950 4L 66.5 60.1 4048.4 0.336 2025 51, 68.0 63.71 4398.71 0.4191 1527 5L 72.01 74.01 5457.51 03571 1617 51, 76.0 86.8 6848.8 0.274 1706 SL 80.0 104.7 8899.6 0.182 7796 51, 84.0 134.91 12545.61 0.095 1886 51. 88.0 276.5 30594.9 0.005 1976 7WLOCKu Flora t Il. IL Vehicle Accel Speed Time Distance Rate (mph) (sec) (ft) (mph/sec) Engine Speed (rpm) iC 4.0 0.7 2.0 5.438 1660 1C 8.0 1.5 9.2 4.462 1733 https://iscaan.al I isontransmission.com/extranetliscaan/SCAANReports?f�-Oct2820l 3_144... 10/28/2013 Page 21 of 21 Note:' Indicates acceleration limited by wheel slip (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al lisontransm ission.com/extranctliscaan/SCA ANReports?€Oct282013_ 144... 10/28/2013 Reliability Driven" ATTACHMENT 1 CNG ENGINE INFORMATION 0 ■ Cooled Exhaust Gas Recirculation (EGR) ■ XPI Fuel System Ir 2 1 F • 6 , ■ VGT Turbocharger • r �` ■ Cummins A % Aftertreatment F 41 System + � a p D' � a ` p ■ Single High -Capacity • ■ Fleetguard' Fuel Filters, G I Electronic Control Lube Filters and Diesel Z �' r 4 Module (ECM) Exhaust Fluid (DEF) Better, Where It Counts. ISL9. Where it counts in the motorcoach industry is on the bottom line. The 2013 ISL9 reduces operating costs with up to 2 percent better fuel economy than the 2012 model, thanks to modifications to the turbocharger and to the addition of an air intake throttle that makes the EGR system more efficient. Lower fuel use results in less carbon dioxide (CO2) emissions. As a result, the ISO meets 2013 U.S. Environmental Protection Agency (EPA) regulations as well as 2014 EPA greenhouse gas (GHG) emissions standards and U.S. Department of Transportation (DOT) fuel -efficiency standards - a full year ahead of schedule. Better Integration. Better Performance. Cummins is the only engine manufacturer to design, develop and support every component from the air intake to the exhaust aftertreatment to work as a totally integrated system. The high-pressure XPI fuel system, with multiple injection events per cycle, is coordinated with the Cummins Aftertreatment System through a single, robust ECM that optimizes everything from throttle response to combustion efficiency to exhaust control. The Cummins Aftertreatment System utilizes proven Selective Catalytic Reduction (SCR) technology, which requires the use of Diesel Exhaust Fluid (DEF) at a rate of approximately 3 percent to 4 percent of diesel fuel consumption. For more information, see the fuel and DEF usage calculator at cummnsengines.com. Fleetguard fuel liters from Cummins Filtration protect against corrosion and contaminants, with proprietary techndogy such as NanoNet'" media, which provides 10 times better protection than conventional fuel fitters. No major hardware changes are needed for 2013, just continuous improvements to our proven technology. The result is a cleaner, more powerful ISL9 engine for every motorcoach. Better Value. Ail Cummins products for the motorcoach market, including diesel and natural gas -fueled engines, are Buy America -compliant. The Cummins ISL9 is manufactured in the United States. Better In The Long Run. Cummins ISL9 has the highest power -to -weight ratio of any engine in Its class, and shares common technology with the Heavy -Duty ISM5 and ISM 2. Heavy-duty roller followers, bypass oil filtration and targeted piston cooling all contribute to longer service, making an ISL9-powered motorcoach a better value in the long run. Better Warranty Coverage. Base engine warranty coverage for Cummins ISL9 engines used in motorcoach applications is 2 years with unlimited miles. It includes 100 percent of all parts and labor on warrantable failures; travel or towing when a vehicle is disabled, plus any consumables not reusable due to the repair - all with no deductible. 'Corers GebCL non MOO r is a factory worbnanMp Every Confidence. For added peace of mind and financial security, Cummins offers an extended coverage plan for the ISL9. Engine coverage includes EGA components, excluding all maintenance components and accessories that bear the name of another company, for terms ranging from 5 years/200,000 miles (321,869 km) to 5 years/500,000 miles (804,672 km). Better Customer Care. Cummins -powered l motorcoaches are backed by the largest and most capable parts and service network in North America, with over 3,500 locations. Our authorized service technicians are trained and certified, and have the necessary equipment and Genuine Cummins Parts to promptly handle any service issue. Plus, Cummins Care representatives are on call 24/7/365 to help you locate the nearest available and authorized facility to service your motorcoach. Cummins Care representatives can also answer questions about your engin, aftertreatment system and related technology. For assistance, just call 1 -800 -DIESELS'" (1-800-343-7357). IS11.9 Ratings Engine AdverBced HP (KVW) Peak Torque Model LB -FT (141•114 ® RPM ISL9 380 380 (283) 1250 (1695) 0 1400 ISL9 Specifications Govemed Speed 2100 r1PM Clutch Engagerrrent Torque 575 L6 -Fr 780 N -M Number of cylinders 6 System Weight 1,912 La 867 KG Engine (Dry) 1,695 LB 769 KG Aftertreatment System' 217 LB 98 KG Inrteese o standard mtA W,, does not irduce des OEM-M40ed components Better. Where H Counts. Cummins ISL9 delivers better performance, increased fuel economy, exceptional reliability and durability and unexcelled service capability. No matter what counts most to you, you can count on Cummins ISL9. For additional details, visit cumminsengines.com or contact your local Cummins distributor or dealer. Cummim B-nos Inc. loluBoa 3005 U.&K u0.lN <)Yl11-1005 U.AA War 1 0'10-pE315*� U mn3a3.TS/1 Fax 1800YlP O Int~ CVmNaa4ws' — T ti6%.f.MYlaI�F1'�191r5 vaa .teGa'nClmreEnlas P lw,197IIM Fr1 USA IM Page I of 21 SCAAN No.: 203744 Description : d4500_ISX12 EPA2013_425HP_373_TC541 Date: 1/30/2013 User: Alvaro Lazcano, MCl/NAC Application Review Status: Output Units: US ALLISON TRANSMISSION INPUT SUMMARY vul ^AVIV Service Bus Ap 'ce8on Intercity Bus C uretion JStraightVehicle Vocation Number 44-25-14 VEHICLE PARAMETERS uesm non End User (and Region, Sub Region) iMotor Coach Industries LTD (North America, Canadian) ManufaGurer (and Region. Sub Region) Motor Coach Industries (North America, Canadian) Model D4500 com Description ID4500 Commuter Area dna, Y nr Power Packs 1 Height 11.40 R) Width 8.50 (ft) Standard Wind Resistance Coefficient (No Deflector) 0.45 User Defined Resistance Coefficient (No Deflector) 0.00 Weight, Rated ( No Trailer, GVW) 50000 (lb) Weight on Drive Wheals 42.00 I%) Weight on Drive Wheels 21000 (lb) 1 MRS Number of Tires 8 Manufacturer ISX12 EPA13 Tire Model & Size 425hp 114501bft 121 m Tire Type Standard Radial Tire Revs 90 (revslmi) Radius 20.58 (m.) Standard Surface Factor 1.0 Smooth Concrete User Defined Surface Factor 0.0 Stnndenl Traction Limit Coefficient (On -Road) 10.7o LNUINC Engine Manufacturer Cummins Model ISX12 EPA13 Description 425hp 114501bft 121 m Certification Year 2013 Peak Torque/Speed 1450.011100 (Ib -ft)/ ) Peak PowedS eed 425.011800 (h )/( ) Governed Power/Speed 397.812100 (h )/( m) Cruise VelocitylSpeed 85.0/1370 (mph)/(rym) Vocation 0 En ine Curve Reference FR20402MC No. Of Curves Single SCAAN File Number 2-1307 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al lisontransm ission.com/extranet/iscaan(SCAANReports?f=Oct282013_ 144... 10/28/2013 Page 2 of 21 HVVCJJVR�GJ r Standard (hp) User (hp) Fan (dutch fan) 57.36 65.00 AIVGeneralor 8.50 12.00 Air Compressor 2.48 1.50 Steer Pump 2.48 1.50 Air Conditioning 0.00 22.00 i RArvomlJJwn Manufacturer Allison Configuration 8500 (1.6)(1-500-3) Convener TC541 (NOT RECOMMENDED- Smoke Control) (1-541-1) Retarder 303.7 Shut Calibration 2100 rpm S1/55 Pert. Std Preselects, (1$ (1-500-2100-1003) Rating Intercity Coach w/41h 8 5th Gen Controls (1-500-4) UKIVt,LINI, Propshaa DnveAxles Sid Efficiency 98.60(%) Axle 6x2 On Hwy Single Red Manufacturer 303.7 Description 284.4 Ratio Description Single Ratio 3.730 Std Efficiency 97,00(%) Overall Driveline 309.3 Ratio 13.730 Std Effciency195.64(%) GRADES Std Acceleration 0.00 (k) ENGINE DETAIL - Standard Accessories (AC On where applicable) Law Ana rn n 1Uwe1 Speed Power Torque (rpm) (hp) I (Ib -ft) Fan On/AC On Net Power (hp) Fan On/AC On Net Torque (Ib -ft) Fan Off/AC On Net Power (hp) Fan Off1AC On Net Torque hb-ft) 1100 303.7 11450.0 284.4 1357.8 292.6 1397.2 JPeakTorque 1200 331.3 11450.0 309.3 1353.7 320.0 140D.5 1300 358.9 11450.0 333.8 1348.5 347.4 1403.4 1400 386.5 11450.0 357.8 1342.1 374.8 1405.9 1500 414.1 11450.0 381.2 1334.8 402.1 1408.0 1600 429.6 11410.0 1392.0 1286.6 417.3 1369.8 1700 430.5 1330.0 387.6 1197.5 418.0 1291.5 1800 425.0 1240.0 376.2 1097.6 412.3 1202.9 Peak Power 1900 419.6 1160.0 364.3 1006.9 406.7 1124.2 2000 411.3 1080.0 348.6 915.4 398.1 1045.4 2100 397.8 995.0 327.1 818.1 384.4 1961.5 JGovemed 2300 0.0 0.0 -89.2 -203.6 -13.9 1.31.7 INO Load Governed Peak Power point has been defined for the purposes of assessing Accessory Losses This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. h ttps://iscaan.al I isontransm iss ion.com/extranetliscaan/SC AANReports?f=Oct282013_144... 10/28/2013 Page 3 of 2l ENGINE DETAIL - User Defined Accessories (AC On where applicable) r.aw nnu m r ruwcr Speed Power Torque (rpm) Ihp) (laff) Fan On/AC On Net Power (hp) Fan On/AC On Net Torque (Ib -ft) Fan OMAC On Net Power (hp) Fan OffIAC On Net Torque (Ito 1100 303.7 11450.0 269.3 1285.6 278.6 1330.2 Peak Torque 1200 331.3 11450.0 292.9 1281.9 305.0 1335.0 1300 358.9 1450.0 316.0 1276.7 331.4 1339.0 1400 386.5 11450.0 338.6 1270.2 357.9 1342.5 1500 414.1 11450.0 360.6 1262.5 384.3 1345.5 1600 429.6 11410.0 369.8 1213.7 398.5 11308.1 1700 430.5 11330.0 1363.8 1123.9 398.3 1230.4 1800 425.0 1240.0 350.6 1023.0 391.6 1142.5 Peak Power 1900 419.6 1160.0 336.9 931.2 385.0 1064.3 2000 411.3 1080.0 319.3 838.5 375.5 986.0 2100 397.8 995.0 1295.B 739.9 360.8 902.5 Governed 2300 0.0 0.0 -124.8 -284.9 .39.4 -89.9 No Load Governed Peak Power point has been defined for the purposes of assessing Accessory Losses This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al I i sontransm iss ion.com/extranet/iscaan,/SCAANReports?1=0ct282013_ 144... 10/28/2013 Page 4 of 21 SCAAN No.: 203744 Description d4500_ISX12_EPA2013_425HP 373 TC541 Date . 1130/2013 User: Alvaro Lazcano, MCI/NAC Application Review Status Output Units US ALLISON TRANSMISSION SCAAN SUMMARY Based On Standard Parameters Vocation: Bus, Intercity Bus. Straight Vehicle End User: Motor Coach Industries LTO (North America, Canadian) Manufacturer: Motor Coach Industries (North America, Canadian) Model: D4500 cam, D4500 Commuter Engine: Cummins ISX12 EPA13 425hp t 14501bft 12100rpm Engine Certification Year: 2013 Transmission: B500 (1E) Rating. Intercity Coach wAth & 5th Gen Controls Converter: TC541 (NOT RECOMMENDED -Smoke Control) Retarder. unrvancr Check Check Name Recomm/Rating Units Min/ Max Actual Overall Status C1 Transmission/Converter Compatibility 35.5 Max V13 Status OK C2 Engine/Converter Compatibility 4.039 V14 1st Range 80% Converter Efficiency Gradeability 18.0 OK OK C4 Engine Speed At Converter Stall V17 rpm mph 1628 T2 C9 Engine Speed At Converter Stall, Smoke Control 1825 rpm Min 1628 XX C5 Minimum Engine Speed 1200 rpm Min 1528 OK C7 Turbine Torque At Stall 2450 Ib -ft Max 2347 OK C8 Converter Speed Ratio at 2100 rpm 0.800 Min 0.916 OK C3 Converter Stall Torque Ratio hp Max I 1.897 T14 r rar wwwavrr Check Check Name RecommlRating Units Mini Actual overall 1 at Range Converter Stall Gradeability percent Actual 35.5 Max V13 Status T1 TransmissionNocation Compatibility 23.9 4.039 V14 1st Range 80% Converter Efficiency Gradeability 18.0 OK Min Transmission Compatible with High Torque Rise Diesel OK V17 Maximum Geared Vehicle Speed At Engine Governed Speed mph OK T2 Engines V18 Maximum Speed on 0.50% Grade 65.0 mph Min 89.4 T20 Torque Limiting: Engine & Transm SEM/LRTP Read Heat Generated in 1 at Range 70% Converter Efficiency 8tutmin 5259 OK V44 Transmission Permitted in End User/Chassis Mfg Btulmin 3684 OK T17 Locations T15 Input Power(Gross) 550 hp Max 431 OK T14 Input Torque(Gross) 1700 Ib -ft Max 1450 OK T3 Input Speed (Engine Governed Speed) 1700/2300 rpm 2100 OK T4 Transmission Output Speed rpm 3266 vemcreivnvw-nw Check Check Name Recomm/Rating Units Mini Max Actual Overall Status V21 1 at Range Converter Stall Gradeability percent Actual 35.5 V13 1st Range 70% Converter Efficiency Net Gradeability percent Status 23.9 4.039 V14 1st Range 80% Converter Efficiency Gradeability 18.0 percent Min 20.5 OK V17 Maximum Geared Vehicle Speed At Engine Governed Speed mph 1029 V18 Maximum Speed on 0.50% Grade 65.0 mph Min 89.4 OK V43 Heat Generated in 1 at Range 70% Converter Efficiency 8tutmin 5259 V44 Heat Generated in 1st Range 80% Converter Efficiency Btulmin 3684 Vefncie/OnveOne/Fue/ Economy Check Check Name RecommlRating Units Mini Actual overall Max Status V57 Maximum Driveline Ratio for Optimum Engine Speed 4.039 Max 3.730 OK V59 Gradeability at 65.0 mph Cruise Velocity 0.50 percent Min 2.65 OK https://iscaan.all i sontransm iss ion.com/extranet/iscaan/SCAANReports?f--Oct2820l 3_ l 44... 10/28/2013 Page 5 of 21 Min 1 9.7 OK: Acceptable OK -t: OK based on pre -acceptance by Engineering OK -2: OK based on Accepted Application Review C: Consider- manufacturer to assess XX: Ouestlonable - may not be acceptable XXX: Not Acceptable - rating or usage violation This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al I isontransmi ss ion.com/extranet/iscaan/SCAANReports?f=Oct2820l 3_ 144... 10/28/2013 Page 6 of 21 Check Comments C5 (Net peak torque speed . allowable variation is 1100 r 100 rpm) T4 Range 6L at 2100 rpm Engine Governed Speed V17 In 6 Lockup V18 At 2008 rpm Engine Speed, Range 5L V43 At 1759 rpm Engine Speed V44 At 1806 rpm Engine Speed V51 Recommended Ratio based on 6L operation at Cruise Conditions of 65.0 mph at 1370 rpm. Actual Ratio results in 65.0 mph at 1285 rpm. (Engine mfg recommendation is 65.0 mph at 1370 rpm). V60A Actual Gradeabikty in 2L V61 lRecommended 5L -6L Shift Speed is Cruise Speed - 5.0 mph This SGAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https:Hiscaan.all isontransmission.comlextranet/iscaanISCAANReports?fOct282013_144... 10/28/20t' Page 7 of 21 SCAAN No, :203744 Description: d4500_ISX12 EPA2013 425HP 373_TC541 Date: 113012013 User: Alvaro Lazcano, MCl/NAC Application Review Status: Output units: us ALLISON TRANSMISSION SCAAN SUMMARY Based On User Defined Parameters Vocation: Bus, Intercity Bus, Straight Vehicle End User: Motor Coach Industries LTD (North America, Canadian) Manufacturer: Motor Coach Industries (North America, Canadian) Model: D4500 com, D4500 Commuter Engine: Cummins ISX12 EPA13 425hp / 14501bft / 2100rpm Engine Certification Year. 2013 Transmission: 6500 (1-6) Rating: Intercity Coach w/4th & 5th Gen Controls Converter: TC541 (NOT RECOMMENDED - Smoke Control) Retarder: vemcmiunve...nc Check Cheek Name Recomm/Rating Unita Max Actual V21 1st Range Converter Stall Gradeabillty percent 4.039 34.0 V13 1st Range 70% Converter Efficiency Net Gradeabilily percent Gradeability at 65.0 mph Cruise Velocity 23.0 V14 1st Range 80% Converter Efficiency Gradeability 18.0 percent Min 19.7 V17 Maximum Geared Vehicle Speed At Engine Govemed Speed mph 91 107.9 V18 Maximum Speed on 0.50% Grade 65.0 mph Min 87.5 V43 Heat Generated in 1st Range 70% Converter Efficiency Btu/min 5187 V44 Heat Generated in 1st Range 80% Converter Efficiency I Stulmin 3632 vemcrerunveunmrw� cwiwn Check Check Name RecommlRating Units mini I Max Actual V51 Maximum Driveline Ratio for Optimum Engine Speed 4.039 Max 3.730 V59 Gradeability at 65.0 mph Cruise Velocity 0.50 percent Min 2.40 V60A lGradeability at 2C -2L Shift 7.0 percent Min 91 V61 Vehide Speed at 51--61- Shift 60.0 mph Max 91.3 OK. Acceptable OK -1: OK based on pre -acceptance by Engineering OK -2: OK based on Accepted Application Review C: Consider- manufacturer to assess XX: Questionable - may not be acceptable XXX: Not Acceptable - rating or usage violation This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https:lliscaan.al li sontransmission.com/extranetliscaanISCAANReports?1=0ct2820l3_ 144... 10/28/2013 Page 8 of 21 YCheck Comments Viz In 6 Lockup V18 At 1966 rpm Engine Speed, Range 5L V43 At 1751 rpm Engine Speed V44 At 1797 rpm Engine Speed V51 Recommended Ratio based on 6L operation at Cruise Conditions of 65.0 mph at 1370 rpm. Actual Ratio results in 65.0 mph at 1265 rpm. (Engine mfg recommendation is 65.0 mph at 1370 rpm). V60A Actual Gradeability in 2L V61 Recommended 51--61- Shin Speed is Cruise Speed - 5,0 mph This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https:#iscaan.al I isontransm ission.com/extranet/iscaanISCAANReports?f=Oct282013_144... 10/28/2013 Page 9 of 21 SCAAN No.: 203744 Description: d4500_ISX12_EPA2013_425HP_373_TC541 Date: 1/30/2013 User: Alvaro Lazcano, MCl/NAC Application Review Status Output Units: US ALLISON TRANSMISSION CUSTOMER PERFORMANCE SUMMARY Based an Standard Parameters Vocation: Bus, Intercity Bus, Straight Vehicle End User. Motor Coach Industries LTD (North America, Canadian) Manufacturer: Motor Coach Industries (North America, Canadian) Model: D4500 com, D4500 Commuter Engine: Cummins ISX 12 EPA13 425hp 114501bft / 2100rpm Engine Certification Year. 2013 Transmission: 8500 (1-8) Rating: Intercity Coach w/4th & 5m Gen Controls Converter. TC541 (NOT RECOMMENDED - Smoke Control) Retarder: Weight: 50000 (Ib) (GVW) Driveline Ratio: 3.730 Tires: Standard Radial Tire, 490.0 (revs/ml) Geared Speed: 107.9 (mph) 6L Clutch Fan Status : Fan On Air Conditioning Status: No AC uraaemwr Launch GradeabBlty 33.5(%) Tow Gradeability 20.5(%) at 10.1 (mph), 80(%) Conv Efi Grade Maximum Speed On Grade 0.00(%) at 93.3(mph), 6L, Road Load Speed 0-50 (mph) 0.25(%) at 88.0(mph), 5L (mph) 0.50(%) at 85.6(mph). 5L 1.00(%) at 80.7(mph), 5L 2.00(%) at 70.6(mph). 5L 3.00(%) at 59.7(mph), 4L 4.00(%) at 52.2(mph), 4L 5.00(%) at 42.6(m h), 3L 6.00(%) at 39.4(mph), 3L .00(%) at 32.4(m h), 2L 8.00(%) at 31.2(mph). 2L 9.00(%) at 28.0(m h), 2L 10.00(%) at 20.2(mph), 2C nccerereuan run unwae, .. 0 Time And Distance To Speed, 0(%) Grade -20 (mph) in 5.5(sec) 98(R 0-30 (mph) in 10.8(sec) 293(5) 0-40 (mph) a0.60 in 1 8.0(sec) 666(ft) 0-50 (mph) in 28.4(sec) 1352(ft) (mph) in 41.6(sec) 2431 ft This SCAAN information Is subject to the SCAAN Disclaimer set forth elsewhere. https:Hiscaan.al lisontransmission.com/extranet/iscaanISCAANReports?f—�Oct282013_144... 10/28/2013 Page 10 of 21 SCAAN No. :203744 32.0(% Description: d4500_ISX12_EPA2013_425HP_373_TC541 Date: 1/30/2013 Maximum Speed On Grade User: Alvaro Lazcano, MCVNAC 0-50 (mph) Application Review Status: 0-60 (mph) Output Units : US - ALLISON TRANSMISSION 2.00(%) at 67.3(mph), 61- L3.00(%) CUSTOMER PERFORMANCE SUMMARY 3.00(%)at 57.2(mph), 4L Based on User Defined Parameters Vocation: Bus, Intercity Bus, Straight Vehicle End User: Motor Coach Industries LTD (North Amence, Canadian) Manufacturer: Motor Coach Industries (North America, Canadian) Model: D4500 com, D4500 Commuter Engine: Cummins ISX12 EPA13 425hp / 14501bfi / 2100rpm Engine Certification Year: 2013 Transmission: 8500 (1-6) Rating: Intercity Coach w/4th 8 5th Gen Controls Converter: TC541 (NOT RECOMMENDED - Smoke Control) Retarder. Weight: 50000 (lb) (GVW) Dnveline Ratio: 3.730 Tires: Standard Radial Tire, 490.0 (revs/mi) Geared Speed: 107.9 (mph) 61- Clutch L Clutch Fan Status: Fan On Air Conditioning Status : On Launch Gradeability 32.0(% Low Speed Gradeability 19.7(%) at 9.9(mph), 80(%) Conv Eff Grade Maximum Speed On Grade 0.00(%) at 88.2(mph), 5L, Road Load Speed 0-50 (mph) 0.25(%) at 85.8(mph), 51 0-60 (mph) 0.50(%) at 83.4(mph), 51 1.00(%) at 78.6(mph), 5L 2.00(%) at 67.3(mph), 61- L3.00(%) 3.00(%)at 57.2(mph), 4L 4.00(%) at 47. (mph). 4L 5.00(%) at 41.0(mph), 3L 6.00(%) at 37.4(mph), 3L 7.00(%) at 31.8(mph), 2L 8.0%%) at 29.6(mph), 2L 9.00(%) at 24.9(m h), 2L 10.00(%) at 18.8(mph), 2C ,o1-ravon Mul/ r6mMrn brakes 101"4 -1-41 Time And Distance To Speed. 0(%) Grade 0-20 (mph) In 5.8(sec) 103(ft) 0-30 (mph) in 11.4(sec) 312(R) 0-40 (mph) in 19.2(sec) 714(1t) 0-50 (mph) in 30.5(sec) 1462(ft) 0-60 (mph) in 45.1 sec) 2646(1) This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al Iiso ntransm ission.com/extranet/iscaart/SCAANReports?FOcO 82 01 3_ 144... 10/28/2013 SCAAN No.: 203744 Description: d4500_ISX12_EPA2013_425HP_373 TC541 Date: 1/30/2013 User: Alvaro Lazcano, MCI/NAC Application Review Status Output Units : US ALLISON TRANSMISSION VEHICLE FULL THROTTLE PERFORMANCE Based on Standard Parameters Transmission Input Ratio : 1.0000 Transmission Input Efficiency (%): 100.00 Clutch Fan Status: Fan On Axle Ratio: 3.730 Air Conditioning Status: No AC Auxiliary Gearing Ratio: 1.000 Power Packs: 1 Page I I of 21 n1 or 11 _Or _el -91-Al 1 Vehicle Speed (mph) I Engine Speed (rpm) Tractive Effort (lb) Drawbar Pull (lb) Wheel Power (hp) Net% Grade (%) Transm Heat Rel (Btulmin) RIC 0,01 1628 22626 22414 0.0 50.1 16575 ' RIC 4.01 1719 17802 17579 189.9 37.6 7927 ' RIC 5.71 1759 15904 15674 241.0 33.0 5466 70Percent RIC 7.4 1806 13789 13553 270.4 28.2 3934 80Percen RIC 8.0 1825 13006 12768 277.5 26.4 3525 80Percent RIC 8.7 1841 12279 12037 284.0 24.8 3154 85Percent RIC 12.0 1973 8614 8357 275.7 17.0 2740 RIC 13.2 2100 7531 7269 264.2 14.7 2157 Governed R1C 15.3 2253 0 -2741 0.0 -0.5 692 n1 or 11 _Or _el -91-Al 1 https://iscaan.al I isontransm ission.com/extranet/i scaan/SCAANReports?1=Oct282013_ 144... 10/28/2013 V Vehicle" Speed (Mph) Engine Speed (rpm) Tractive Effort (lb) Drawbar Pull (Ib) Wheel Power Ihp) Net% Grade M Transm Heat Rel (Btulmin) 1C 0.0 1628 16955 16743 0.0 35.5 16575 ' 1C 4.0 1690 14162 13939 151.1 290 9761 1C 7.8 1759 11874 11637 246.1 23.9 5239 70Percent 1C 8.0 1763 11718 11479 250.0 23.6 5048 1C 10.1 1806 10295 10047 276.1 20.5 3680 80Percent 1C 11.91 1841 91641 8908 289.9 18.1 2893 85Percent 1C 12.0 1843 9084 8827 290.7 17.9 2848 1C 14.7 1909 7454 7183 293.0 14.5 2396 20 14.7 1763 6376 6105 250.6 12.3 5019 2C 16.0 1777 6116 5838 261.0 11.8 4494 2C 20.0 1823 5309 5006 283.2 10.1 3280 2C 24.0 1867 4594 4263 294.0 8.6 2576 2C 24.2 1871 4552 4219 294.1 8.5 2557 2L 24.2 1407 6149 4816 332.7 9.7 488 2L 28.0 1626 48401 4477 361.4 9.0 552 2L 32.0 1858 39741 3576 339.1 7.2 624 2L 34.0 1975 3549 3133 321.9 6.3 677 3L 34.0 1480 3850 3434 349.2 6.9 487 3L 36.0 1567 3750 3314 360.0 6.6 510 3L 40.0 1741 3317 2840 353.9 5.7 549 3L 44,0 1915 2832 2310 332.3 4.6 611 3L 46.0 2000 2600 2054 318.7 4.1 649 41- 46.01 1400 2721 2175 333,51 4.4 384 41- 48.01 1462 2715 2144 347.5 4.3 381 !L152.0 1584 2628 2005 364.4 4.0 392 4: 56.0 17061 24151 1737 36061 3.5 4211 1 41- 60.01 18281 21651 1429 346.4F-2.9 4551 1 https://iscaan.al I isontransm ission.com/extranet/i scaan/SCAANReports?1=Oct282013_ 144... 10/28/2013 Page 12 of 2 t 4LI 64.01 1950 19321 1135 329.81 2.3 495 4LI 66.51 2025 17841 947 316.31 1.9 529 51-1 66.51 1493 19721 1135 349.61 2.3 593 5L 68.01 1527 19511 1089 353.81 2.2 602 5L 72.0 1617 18741 944 359.81 1.9 637 5L 76.0 1706 17511 749 364.81 1.5 674 5L 80.0 1796 1614 537 344.21 1.1 707 SL 84.0 1886 1488 333 333.41 0.7 737 5L 88.D 1976 1362 125 319.61 0.3 770 5L 91.3 2050 1253 -53 305.2 -0.1 7981 1 6L 91.3 1777 1401 95 341.2 0.2 937 6L 92.0 1791 1383 61 339.3 0.1 953 6L 96.0 1869 1287 -123 329.4 -0.2 999 6L 100.0 1946 1191 -310 317.6 -0.6 1055 6L 104.0 2024 1093 -503 303.2 -1.0 1118 6L 107.9 2100 994 -698 286.0 -1.4 1193 Governed 6L 108.0 2102 979 -716 282.0 -14 1193 6L 112.0 2180 453 -1343 135.3 -2.7 1206 6L 115.4 2247 0 -1886 0.0 -3.81 1215 7W LOCKUD HOIO Ili -IL Vehicle Speed (mph) Engine Speed (rpm) Tractive Effort (lb) Drawbar Pull (lb) Wheel Power (hp) Net % Grade 1%) Transco Heat Rej IBtulmin) 1C 0.0 1628 16955 16743 0.0 35.5 16575 ' 1C 4.0 1690 14162 13939 151.1 29.0 9761 1C 7.8 1759 11874 11637 246.1 23.9 5239 70Percent 1C 8.0 '1763 11718 11479 250,0 23.6 5048 IC 10.1 1806 10295 10047 276.1 20.536801 80Percenl 1C 11.91 1841 91641 8908 289,911 18.1 2893 85Percenl 121 12.0 1843 9084 8827 290.7 17.9 2848 1C 12.8 1860 8609 8349 293.2 16.9 2652 1L 12.8 1365 9480 9220 322.8 18.8 506 1L 16.0 1711 8323 8045 355.1 16.3 639 IL 19.6 2100 5631 5330 294.9 10.7 796 Govemetl 1L 20.0 2139 4209 3906 224.5 7.8 778 1L 21.11 2252 0 -310 0.01 715 Note :' Tractive Effort exceeds vehicle traction limit (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 Note: Requested AC On Report is not included because AC Loss is 0.0 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.al l isontransm ission.com/extraneLliscaan/SCAANReports?f=Oct282013_ 144... 10/28/2013 SCAAN No.: 203744 Vehicle Speed (mph) Descnpfion: d4500_ISX12_EPA2013_425HP_373_TC541 Tractive Effort fib) Date: 1 /3 012 01 3 Wheel Power (hp) User: Alvaro Lazcano, MCI/NAC Transm Heat Rej (Btu/min) Application Review Status Ric Output Units US 1621 22422 ALLISON TRANSMISSION 0.0 VEHICLE FULL THROTTLE PERFORMANCE 16353 ' Based on User Defined Parameters Transmission Input Ratio : 1.0000 Transmission Input Efficiency (%): 100.00 Clutch Fan Status : Fan On Azle Ratio'. 3.730 Air Conditioning Status : OH Auxiliary Gearing Ratio: 1.000 Power Packs:1 Page 13 of 21 ^ Vehicle Speed (mph) Engine Speed (rpm) Tractive Effort fib) Drawbar Pull (lb) Wheel Power (hp) Net % Grade 1%) Transm Heat Rej (Btu/min) ICI Ric 0.0 1621 22422 22210 0.0 49.6 16353 ' icl R1C 4.0 1711 17622 17399 188.0 37.1 7791 ' icl RiC 5.7 1751 15751 15522 237.6 32.7 5390 70Percenl R1C 7.3 1797 13650 13414 266.3 27.8 3878 80Percent RlC 8.0 1815 12823 12584 273.5 26.0 3458 IC RIC 8.6 1831 12150 11909 279.5 24.5 3109 85Percenl R1C 12.0 1968 447 8 8190 270.3 16.6 6701 1 R1C 13.2 21001 73091 70451 257.21 14.2 2077 Governed R1C 15.2 2248 0 -2741 0.0 -0.5 686 2C IIYIYIl10114 Vehicle Engine Speed Speed (mph) I (rpm) Tractive Effort als) Drawbar Pull (lb) Wheel Power (hp) Net % Grade 1%) Transm Heat Raj (Btulmin) ICI 0.01 1621 15802 16590 0.0 35.2 16353 ' icl 4.01 1683 14018 13795 149.5 28.7 9591 icl 7.71 1751 11760 11522 242.6 23.7 5166 70Percent 1C 8.01 1756 11578 11339 247.0 23.3 4946 1C 10.0 1797 10190 9943 271.9 20.3 3629 80Percent IC 11.8 1831 90671 8812 285.31 17.9 2852 85Percent I 12.0 1834 8950 8693 286,41 17.7 2787 1C 14.7 1901 7322 7051 287.81 14.2 2365 2C 14.7 1756 6300 6029 247.6 12.1 4917 2C 16.0 1769 6040 5762 257.71 11.6 44001 1 2C 20.0 1814 5234 4931 279.21 9.9 3217 2C 24.0 1859 4519 4187 28921 8.4 2527 20 24.2 1862 4479 4146 299AI 8.3 2504 2L 24.2 1407 5083 4750 328.4 9.5 487 2L 28.0 1626 47681 4405 356.0 8.8 550 2L 32.0 1858 38941 3496 332.3 7.0 622 2L 34.0 1975 34651 3048 314.2 6.1 674 3L 34.0 1480 38001 3383 344.6 6.8 485 3L 36.0 1567 36971 3261 355.0 6.5 509 3L 40.0 1741 32611 2784 347.9 5.6 547 3L 44.0 1915 27711 2248 325.1 4.5 609 3L 46.0 2000 2536 1990 310.8 4.0 647 4L 46.0 1400 2686 2140 329.2 4,3 384 4L 48.0 1462 2679 2109 343.0 4.2 381 4L 52.0 1584 2591 1968 359.3 3.9 392 4L 56.0 1706 2376 1698 354.8 3.4 421 4L 60.0 1828 2124 1388 339.8 2.8 454 hups://iscaan.al lisontransrnission.com/extranet/iscaan/SCAANReports?€Oct282013_ 144... 10/28/2013 Page 14 of 21 41. 64.01 1950 18881 1091 322.21 2.2 495 4L 66.5 2025 17381 901 308.21 1.8 528 5L 66.5 1493 19461 1109 344.91 2.2 592 51 68.0 1527 19251 1062 349.01 2.1 600 5L 72.0 1617 18471 916 354.61 1.8 635 5L 76.0 1706 17221 720 349.11 1.4 672 5L 80.0 1796 15841 507 337.91 1.0 705 51., 84.0 1886 1457 302 326.41 0.6 734 51- 88.0 1976 1329 93 311.91 0.2 767 51-1 91,31 2050 1219 -87 296.8 -0.2 795 6LI 91 .31 1777 1376 69 335.01 0.1 935 6L 92.0 1791 1357 36 333.01 0.1 951 6L 96.0 1869 1260 -150 322.6 -D.3 996 6L 100.0 1946 1163 -338 310.2 -0.7 1051 6L 104.0 2024 1064 -532 295,1 -1.1 1115 6L 107.9 2100 963 -728 277.2 -1.5 1189 Governed 6L 108.0 2102 948 -746 273.1 -1.5 1190 61. 112.0 21801 421 -1375 125.7 -2.8 1202 6L 115.2 2242 D -1 B80 0.0 -3.8 1210 lsr coclfu rrwu r4-eL Vehicle Speed (mph) Engine Speed (rpm) Tractive Effort Pb) Drawbar Pull (lb) Wheel Power (hp) Net % Grade %) Transm Heat Rej (Btulmin) 1C 0.0 1621 16802 16590 0.0 35.2 16353 ' 1C 4.0 1683 14018 13795 149.5 28.7 9591 1C 7.7 1751 11760 11522 242.6 23.7 5166 70Percent I 8.0 1756 11578 11339 247.0 23.3 4946 80Percenl 1C 10.0 1797 10190 9943 271.9 20.3 3629 80Percenl I 11.8 1831 9067 8812 285.3 17.9 2852 85Percent 1C 12.0 1834 8950 8693 286.4 17.7 278711 1 1C 12.8 1852 8472 8211 288,5 16.6 2599 Governed 1L 12.8 1365 9358 9098 318.7 18.5 504 iL 16.0 1711 8188 7910 349.4 16.0 536 1L 19.6 2100 5463 5163 286.1 10.4 792 Governed IL 20.0 2139 4038 3734 215.3 7.5 774 1L 21.0 2248 0 -310 0.0 -0,6 713 Clutch Fan Status : Fan On Air Conditioning Status . On Axle Ratio: 3.730 Auxiliary Gearing Ratio: 1.000 neverse nn, Vehicle Speed (mph) I Engine Speed (rpm) Tractive I Effort (lb) Drawbar Pull (lb) Wheel Power (hpI I Net% Grade M Transm Heat Rej jBtu/min) RIC 0.01 1596 21787 21575 0.01 47.8 15671 ' RIC 4.0 1689 17061 16837 182.0 35.6 7388 ' RIC 5.6 1726 15320 15091 227.8 31.7 5181 70Percenl RIC 7.2 1772 13258 13023 255.2 27.0 3711 80Percenl RIC 8.0 1793 12326 12088 263.0 24.9 3251 R9R1 8.5 1803 11802 11561 267.4 23.6 2995 85Percent 12.0 1958 8045 7789 257.4 15.8 24431 1 13.3 21 Dg 6780 6517 240.3 13.1 1893 Governed 15.1 2237 0 -273 0.0 -0.51 684 Vehicle Engine Tractive Drawbar Wheel Net% Transm Speed I Speed I Effort I Pull I Power Grade Heat Rej https://iscaan.ai Iisontransm ission.com/extranet/iscaan/ SCAANReports?f=Oct282013_144... 10/28/2013 Page 15 of 21 https://i scaan.al I isontransm ission.com/extranet/iscaan/SC AANReports?1=Oct282013_ 144... 10/28/2013 (mph) (rpm) 11b) I (lb) (h ) (%) (Btulmin) Transm Heat Raj (Btulmin) /C 0.0 1596 163271 16115 0.0 34.0 15671 ' 15671 ' 1 C 4.0 1660 135801 13357 144.9 27.7 9107 9107 1C 7.6 1726 114371 11200 232.6 23.0 4968 70Percent 1C 8.0 1733 111801 10942 238.5 22.4 4666 4666 1C 9.9 1772 98971 9650 260.5 19.7 3474 80Percent 1C 11.6 1803 8807 6552 272.9 17.4 2751 85Percent 1 C 12.0 1810 8583 8326 274.7 16.9 2634 1 C 14.7 1879 6972 6701 274.0 13.5 2261 2CI 14.71 1734 6084 5812 239.11 11.7 4639 2C 16.0 1747 5826 5547 248.61 11.2 4142 20 20.0 1791 5031 4728 268.31 9.5 3021 2C 24.0 1836 4322 3991 276.61 8.0 2392 2C 24.2 1839 4284 3951 276,81 7.9 2369 2L 24.2 1407 4866 4533 314.41 9.1 481 2L 28.0 1626 4552 4189 339.91 8.4 544 2L 32.0 1858 3678 3280 313.81 6.6 615 2L 34.0 1975 3248 2831 294.61 5.7 667 31-1 34.01 1480 3637 3220 329.91 6.5 481 3LI 36.01 1567 3535 3099 339,41 6.2 505 3L 40.0 1741 3099 2621 330.51 5.2 543 3L 44.0 1915 2608 2086 306.0 4.2 604 3L 46.0 2000 2373 1827 290.8 3.7 642 4L 46.0 1400 2572 2026 315.2 4.1 384 4L 48.0 1462 2565 1994 328.3 4.0 381 4L 52.0 1584 2476 1854 343.4 3.7 392 4L 56.0 1706 2261 1584 3327 3.2 421 4L 60.0 1828 2009 1273 321.5 2.5 454 41-1 64.01 1950 1774 977 302.7 2.0 495 4LI 66.51 2025 1624 787 287.9 1.6 528 5L 66.5 1493 18621 1025 330.1 2.1 587 5L 68.0 1527 1841 979 333.8 2.0 595 5L 72.0 1617 1763 833 338.5 1.7 630 5L 76.0 1706 1639 637 332.1 1.3 666 5L 80.0 1796 1500 423 320.1 0.8 699 5L 84.0 1886 1373 218 307.6 0.4 7281 1 5L 88.0 1976 1246 9 292.3 0.0 7601 1 5L 91.3 2050 1135 -171 276.4 -0.3 788 5L 91.3 1777 1303 -3 317.3 -0.0 928 6L 92.0 1791 1285 -37 315.2 -0.1 944 6L 96.0 1869 1188 -222 304.0 -0.4 989 6L 100.0 1946 1091 -411 290.9 -0.8 1044 6L 104.0 2024 991 -605 275.0 -1.2 1107 6L 107.9 2100 891 -801 256.3 -1.6 1181 Governed 6L 108.0 2102 876 -819 252.3 -1.6 1181 6L 112.0 2180 349 -1448 104.1 -2.9 1194 -61U-114 .6 2231 0 -1865 0.0 -3.7 1200 https://i scaan.al I isontransm ission.com/extranet/iscaan/SC AANReports?1=Oct282013_ 144... 10/28/2013 u" Vehicle Speed (mph) v Engine Speed (rpm) Tractive Effort (lb) Drawbar Pull (lb) Wheel Power (hp) Net % Grade M Transm Heat Raj (Btulmin) 1C 0.0 1596 16327 16115 0.0 34.0 15671 ' 1C 4.0 1660 13580 13357 144.9 27.7 9107 1 C 7.6 1726 11437 11200 232.6 23.0 4968 70Percent 1C 8.0 1733 11180 10942 238.5 22.4 4666 1C 9.9 1772 9897 9650 260.5 19.7 3474 80Percent https://i scaan.al I isontransm ission.com/extranet/iscaan/SC AANReports?1=Oct282013_ 144... 10/28/2013 Page 16 of 21 iC 11.61 1803 88071 8552 272.91 17.4 2751 85P IC 12.0 1810 8583 8326 274.71 16.9 2634 IC 12.6 1830 81007839 275.8 15.9 2468 1 12.8 1365 8961 8700 305.2 17.7 498 1L 16.0 1711 7791 7512 332.4 15.2 628 1L 19.6 2100 5066 4765 265.3 9.6 782 Governed 1L 20.0 2139 3640 3337 194.1 6.7 764 1L 20.9 2237 0 -309 0.0 -0.6 709 Note : ' Tractive Effort exceeds vehicle traction limit (wheelslip passible) using On -Road Traction Limit Coefficient = 0.70 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https://iscaan.alIisontransmission.com/extranet/iscaan/SCAANReports?f-0ct282013_144... (0/28/2013 SCAAN No.: 203744 Description: d4500_ISX12_EPA2D13 425HP_373_TC541 Date : 1/30/2013 User: Alvaro Lazcano, MCIIMAC Application Review Status: Output Units : US ALLISON TRANSMISSION VEHICLE ACCELERATION PERFORMANCE Brakes Looked Start Based on Standard Parameters Transmission Input Ratio: 1.0000 - Transmission Input Efficiency I%): 100.00 Clutch Fan Status: Fan On Air Conditioning Status: No AC Grade: 0.0 percent Axle Ratio: 3.730 Auxiliary Gearing Rabin: 1.000 Power Packs. Palac F of 2I 1C -2C -2L -3L -4L -5L -6L) Vehicle Speed Time (mph) (sec) Accel Distance Rate (it) Imphlseq Engine Speed (rpm) ECR 4.0 211.1.6 6.968 1719 8.0 1.2 7.6 5.038 1825 0.6 12.0 221 22.5 3.0271 1973 1C -2C -2L -3L -4L -5L -6L) Vehicle Speed I Time Distance AccelI Engine Rate Speed https:lliscaan.al lisontransm ission.comlextranetliscaanISCAANReports?f=Oct2820l 3_144... 10/28/2013 Vehicle Speed (mph) Time (sec) Distance (ft) Accel Rate (m hlsoc Engine Speed rpm 1C 4.01 0.6 1.9 5.678 1690 1C 8.01 1.4 8.8 4.683 1763 1C 12.01 2.4 23.3 3.615 1843 1C 14.71 3.2 40.1 2.903 1909 2C 16.0 3.7 51.3 2.481 1777 2C 20.0 5.5 97.5 2.128 1823 2C 24.0 7.51 163.5 1.806 1867 2C 24.2 7.7 167.9 1.789 1871 2L 28.0 9.6 243.0 1.839 1626 2L - 32.0 12.0 350.3 1.470 1858 2L 34.0 13.5 420.9 1.290 1974 31- 36.0 14.9 - 493.5 1.389 1567 3L 40.0 18.0 666.0 1.192 1741 3L 44.0 21.7 896.2 0.970 1915 3L 46.0 23.9 1038.0 0.862 2000 4L 48.0 26.1 1191.4 0.910 1462 4L 52.0 30.6 1523.0 0.852 1584 4L 56.0 35.7 1921.7 0.739 1706 4L 60.0 41.6 2430.8 0.608 1828 4L 64.0 49.0 3102.9 0.484 1950 4L 66.5 54.6 3640.5 0.404 2025 5L 68.0 57.8 3956.2 0.4661 1527 5L 72.0 67.0 4899.7 0.405 1617 5L 76.078.1 6105.6 0.321 1706 5L 80.0 92.8 7788.4 0.231 1796 5L 84.01 114.71 10430.4 0.144 1886 5L 88.01 158.71 15995.4 0.055 1976 Vehicle Speed I Time Distance AccelI Engine Rate Speed https:lliscaan.al lisontransm ission.comlextranetliscaanISCAANReports?f=Oct2820l 3_144... 10/28/2013 Page 18 of 21 Note: " Indicates acceleration limited by wheel slip (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 Note: Requested AC On Report is not included because AC Loss is 0.0 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https:/liscaan.allisontransmission.comlextranet/iscaanISCAANReports?1=0ct2820l3_ 144... 10/28/2013 (Mph) I (sse) I R hkae (rpm) 1C 4.01 0.61 1.9 5.678 1690 1C 8.0 1.41 8.8 4.683 1763 1C 12.0 2.4 23.3 3.615 1843 1C 12.8 2.61 27.3 3.365 1860 1L 16.0 3.61 46.5 2.951 1711 _1L 20.0 5.31 94.6 1.514 2139 Note: " Indicates acceleration limited by wheel slip (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 Note: Requested AC On Report is not included because AC Loss is 0.0 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. https:/liscaan.allisontransmission.comlextranet/iscaanISCAANReports?1=0ct2820l3_ 144... 10/28/2013 SCAAN No. :203744 Description: d4500_ISX12_EPA2013_425HP_373_TC541 Date: 113012013 User: Alvaro Lazcano, MCI/NAC Application Review Status: Output Units: US ALLISON TRANSMISSION VEHICLE ACCELERATION PERFORMANCE Brakes Locked Start Based on User Defined Parameters Transmission Input Ratio: 1.0000 Transmission Input Efficiency (%): 100.00 Clutch Fan Status : Fan On Air Conditioning Status: Off Grade: 0.0 percent Axle Ratio: 3.730 Auxiliary Gearing Ratio: 1.000 Power Packs: 1 Page 19 of 21 rtevelx rtli. I V'C V'LLV �-+='�L'VL Vehicle Speed (mph) Accel Engine Accel Rate Im hlsec) Vehicle Speed Time Distance Rate Speed 1C (mph) (sec) R) (mphisec) (rpm) ERICR 4.0 0.5 1.6 6.898 1711 RIC 8.0 1.2 7.7 4.971 1815 1.4 12.0 2.2 22.9 2.888 1968 HV(Vll1011l: I V'C V'LLV �-+='�L'VL Vehicle Speed (mph) Time (sec) Distance (ft) Accel Rate Im hlsec) Engine Speed (rpm) 1C 4.0 0.7 2.0 5.620 1683 1C 8.0 1.4 8.9 4.626 1756 1C 12.0 2.4 23.6 3.557 1834 1 C 14.7 3.3 40.7 2.851 1901 2C 16.0 3.8 52.0 2.448 1769 2CI 20.0 5.6 98.9 2.097 1814 2C 24.0 7.6 165.9 1.775 1859 2C 24.2 7.8 170.5 1.759 1862 2L 28.0 9.8 246.6 1.810 1626 2L 32.0 12.2 356.1 1.438 1858 2L 34.0 13.7 428.4 1.255 1974 3L 36.0 15.2 502.1 1.367 1567 3L 40.0 18.3 677.7 1.169 1741 3L 44.0 22.1 913.4 0.945 1915 3L 46.0 24.3 1059.4 0.835 2000 4L 48.0 26.6 1215.4 0.895 1462 4L 52.0 31.2 1552.9 0.836 1584 4L 56.0 36.3 1959.8 0.723 1706 4L 60.0 42.5 2482.2 0.591 1828 41- 64.0 50.1 3177.8 0.465 1950 4L 66.5 56.0 3740.0 0.384 2025 68.0 59.3 4063.3 0.455 1527 72.0 68.7 5032.5 0.393 1617 76.0 80.2 6280.0 0.309 17061 180.0 9555LLL 95.6 8044.5 0.218 17961 184.0 119.2 10895.3 0.130 1886 88.0 172.0 17577.7 D.041 1976 Vehicle Speed I Time Distance Accel Engine Rate I Speed https://iscaan.al I isontransmission.com/extranet/iscaan/SCAANReports?f--Oct292013_ 144... 10/28/2013 Page 20 of 21 Clutch Fan Status : Fan On Axle Ratio: 3.730 Air Conditioning Status On Auxiliary Gearing Ratio: 1.D00 Grade. 0.0 percent ROYOIJO R/V (mph) (sec) Ift) (mphlsec) (rpm) 1 C 4.0 0.7 2.0 5.620 1683 1 C 8.0 1.4 8.9 4.626 1756 IC 12.0 2.4 23.6 3.557 1834 IC 12.8 2.7 27.7 3.306 1852 1L 16.0 3.7 49.2 2.902 1711 1L 20.0 5.4 96.5 1.452 2139 Clutch Fan Status : Fan On Axle Ratio: 3.730 Air Conditioning Status On Auxiliary Gearing Ratio: 1.D00 Grade. 0.0 percent ROYOIJO R/V Vehicle Accel Accel Rate (mphlsec) Engine Engine Speed (rpm) 5.438 Speed Time Distance Rate 40 Speed 2.0 (mph) (see) R (mph/sac( 1660 (rpm) EI'R 4.0 1.6 9.2 4.462 1689 1733 8.0 1.2 8.0 4.801 2.5 179 12.0 2.31 24.1 2.6691 1 C 1958 f1VIVIllO41V Vehicle Speed (mph) Time (sec) Distance IHI Accel Rate (mphlsec) 1C Engine Speed (rpm) 5.438 1C 1C 40 0.7 2.0 5.438 1660 IC 8.0 1.5 9.2 4.462 1733 1 C 12.0 2.5 24.5 3.395 1810 1 C 14.7 3.4 42.4 2.709 1879 2C 16.0 3.9 54.2 2.357 1747 2CI 20.0 5.8 103.D 2.012 1791 2C 24.0 8.0 173.1 1.694 1836 2C 24.2 8.1 177.9 1.676 1839 2L 28.0 10.2 257.7 1.721 1626 2L 32.0 12.8 373.6 1.349 1858 2L 34.0 14.4 451.1 1.166 1974 3L 36.0 15.9 528.6 1.299 1567 3L 40.0 19.2 714.2 1.101 1741 3L 44.0 23.3 966.3 0.876 1915 3L 46.0 25.7 1124.5 0.767 2000 4L 48.0 28.1 1289.4 0.846 1462 4L 52.0 33.0 1646.8 0.788 1584 4L 56.0 38.5 2080.9 0.674 1706 4L 60.0 45.1 2645.6 0.542 1828 4L 64.0 53.5 3412.8 0.416 1950 4L 66.5 60.1 4048.4 0.336 2025 5L 68.01 63.7 4398.7 0.419 1527 5L 72.01 74.0 5457.5 0.357 1617 ILR.0 86.8 6848.8 0.274 1706 5L 60.0 104.7 8899.6 0.182 1796 5L 84.01 134.9 12545.6 0.095 1886 5L 88.01 276.5 30594.9 0.005 1976 I dl L4VRU AVIV / VehicleACeel Speed Time Distance (mph) (see) (ft) Rate (mphlsec) Engine Speed (rpm) 1C 4.06.7 2.0 5.438 1560 1C 8.0 1.5 9.2 4.462 1733 https:Hiscaan.al l isontransm i ssion.com/extranetliscaan/SCAANReports?"ct282013_ 144... 10/28/2013 Page 21 Of 21 Note`Indicates acceleration limited by wheel slip (wheelslip possible) using On -Road Traction Limit Coefficient = 0.70 This SCAAN information is subject to the SCAAN Disclaimer set forth elsewhere. haps: //iscaan.aI lisontransm fission.com/e)ctranet/iscaan/SCAANReports?FOct282013_ l 44... 10/28/2013 Reliability Driven" ATTACHMENT K WHEELCHAIR LIFT AND TIE DOWNS 1 �j ii1 s THEWAUA ffA&TA=CW0RPR'OATIOA, mobility products CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. NUVL855RM24 Bridge Plate mm Overall Width with Mounting Brackets- 15975" Overall Front Bonier PlWIF -17.5" I 8.375' �5�t�^ a+ FRONT VIEW Overall Cassettelli 133• SIDE VIEW —8.373• IIIrrT�'( 43.. TOPVIEW Lto 34678 19 3008 The, Wan (oilplit 1 M itlRiaB, d®dlpeans and WKffCWM in Bis Rrah+e ae Awed W 86 00 111( itt Blimp n at to dme d PO= The aa3t CaWaxn rMW 818 Ade 10 mete dBn,IM at ay M rpice I= eat • NHTSA 403 Compliant • Automatic Inboard / Outboard Barriers • 750# Lifting Capacity • Scissor Arm Design Provides Smooth Straight Up and Down Motion Interlocking Handrail Belt Handrail Covers for Safety THE BRAVA .AFI� (ORPORATIOtt. www, braurTmobility, com 1 -800 -THE L/FT 1 Foi Tfie ales/moi /Vosirit You IntemeWo ,Co ate Hdqrs_ PO Bw 310 Wrna x, IN 46996 lIN 43 0 3-5438 1574)9166153 FAX 199)94416)0 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL. INC LiN Platform 2G.W (Raised Position) UP Max 63.00' Max•36.50" Down Max WLHandraHsNotShown Platfrm ed Position) Ground Level SIDE VIEW -TRAVEL LIMITS Overall Width with Mounting Brackets- 15975" Overall Front Bonier PlWIF -17.5" I 8.375' �5�t�^ a+ FRONT VIEW Overall Cassettelli 133• SIDE VIEW —8.373• IIIrrT�'( 43.. TOPVIEW Lto 34678 19 3008 The, Wan (oilplit 1 M itlRiaB, d®dlpeans and WKffCWM in Bis Rrah+e ae Awed W 86 00 111( itt Blimp n at to dme d PO= The aa3t CaWaxn rMW 818 Ade 10 mete dBn,IM at ay M rpice I= eat • NHTSA 403 Compliant • Automatic Inboard / Outboard Barriers • 750# Lifting Capacity • Scissor Arm Design Provides Smooth Straight Up and Down Motion Interlocking Handrail Belt Handrail Covers for Safety THE BRAVA .AFI� (ORPORATIOtt. www, braurTmobility, com 1 -800 -THE L/FT 1 Foi Tfie ales/moi /Vosirit You IntemeWo ,Co ate Hdqrs_ PO Bw 310 Wrna x, IN 46996 lIN 43 0 3-5438 1574)9166153 FAX 199)94416)0 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL. INC Driven SUBJECT D Series Maintenance Manual SECTION 22B Date Page BRAUN WHEELCHAIR LIFT CONTENTS OF THIS SECTION August 2013 226-1 PAGE GENERAL DESCRIPTION ............................................. 22B-3 Components.....................................................22B-3 Lift Operating Instructions ......................................... 22B-5 Control Switch Functions..........................................22B-6 OpenDoor(s)and Secure..........................................22B-6 Manual Operating Instructions ...................................... 22B-7 MAINTENANCE and LUBRICATION ..................................... 22B-10 TROUBLESHOOTING................................................ 22B-16 CONTACT REMOVAL ................................................ 22B-19 CALIBRATION......................................................22B-19 NHTSA OPERATIONS CHECKLIST ..................................... 22B-20 SPECIFICATIONS...................................................22B-20 Copyright 2013 - Motor Coach Industries InYI, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August2013 Page 2213-2 D Series Maintenance Manual THIS PAGE INTENTIONALLY LEFT BLANK Copyright 2013 - Motor Coach Industries Ind, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC Date August 2013 �� D Series Maintenance Manual Page 22B-3 Reliability Dri GENERAL DESCRIPTION The Braun wheelchair lift, located in the N2 curb- side baggage bay, provides wheelchair access to the coach. The lift is powered by an electrically -operated hydraulic pump, with manual backup, and operated with a control pendant. Keyed access and a safety in- terlock prevent unsafe deployment. Components Wheelchair Lift The wheelchair lift is located in the curbside of the N2 baggage bay and is accessed through a separate, hinged door. For maintenance, it is accessed through the full-size baggage bay doors. The lift platform has a non-skid surface with a front roll stop and a rear bridge plate. The roll stop and bridge plates lower to serve as ramps when boarding passengers, and act as barriers when the lift is in motion. The platform has two hinged handrails that lock upright. A safety belt is attached to the handrails. The platform cannot be raised or lowered unless the safety belt is buckled. Figure 1. Components kem Description Item Description I Control Pendant (Not Shown) 6 Two -Stage Outer Barrer 2 Inner Roll Stop 7 Lifting Arms 3 Horizontal Arms 8 Torque Tube 4 Shield Handrail with Stop 9 Hydraulic Cylinders 5 Outer Barrier Actuator 10 Manual Platform Release Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August 2013 Page 228-4 D Series Maintenance Manual A carriage assembly is mounted to the rear of the platform. The carriage assembly includes gear motor, components that extend/retract the lift, and a hydraulic cylinder that raises/lowers the lift. The carriage assem- bly is housed in the traveling frame, which moves on guide rails. The entire lift is housed in a cassette, which is mounted to the coach. Control Box The control box is located in the Mt curbside bag- gage bay. The alarm is mounted on top of the control box. Inside, the control box holds the hydraulic pump with electric motor, the manual pump with release valve and detached pump handle, the hydraulic fluid reservoir, and the solenoid and circuit breakers. Wheelchair Lift Master Switch The wheelchair lift master switch is either a key switch or toggle switch located on the upper left of the driver's instrument panel. The master switch must be on to enable lift operation and energize the safety inter- lock circuits. Lift Housing The lift housing is the metal structure (casing) mounted under the vehicle which contains and protects the platform carriage assembly. The housing contains all lift components except the power (pump) module when the lift is in the stowed position. Platform Carriage Assembly The platform carriage assembly includes the plat- form assembly, the lifting arms, and the rolling horizon- tal arms that carry the platform assembly in and out of the housing and the electdcal/hydraulic drive compo- nents that power the lift. Platform Assembly The lift platform assembly consists of the flat alumi- num plate upon which the wheelchair is positioned, the outer barriers, the inner roll stop, and shield handrails. Hand-held Pendant Control DOOR STOW O DOWN UP O O O�nrrw mama 11237 Figure 2. Hand-held Pendant Control 1=711 The hand-held attendant's pendant control is equipped with four push button switches (DOOR, STOW, DOWN, and UP). The momentary switches ac- tivate the automatic lift functions. Simply press the switch labeled for the intended function. When there is power to the lift, the lift function labels illuminate to identify the functions. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date ii Driven' D Series Maintenance Manual Page Threshold Warning System Lift Operating Instructions 1 2 3 4 5 44074 Threshold Warning Module Item Description 1 Light Switch Pushbutton 2 1 Light 3 Air Vent 4 Sensor 5 Threshold Hold Light 6 Stop Pushbutton 7 Speaker The threshold warning system module is installed at the top of the doorway above the lift compartment. The module is turned on when the lift is powered, illu- minating the status indicator. The acoustic sensors are enabled when the door is open and the coach interlock system requirements are met. Acoustic sensors monitor the doorway threshold area for the presence of a passenger or object, such as a wheelchair. The audible buzzer and flashing red light are actuated if someone is detected in the threshold ar- ea when the platform is 1 in. (25 mm) or more below the floor. This system wams lift passengers when the platform is below floor level. The platform must be at floor level when a passenger is boarding or exiting the platform. August2013 22B-5 Before lift operation, park the vehicle on a level surface, away from vehicular traffic. Place the vehicle transmission in Park and engage the parking brake. Open manual doors fully, being certain the doors are secured in the fully open position. It is the responsibility of the lift operator (attendant) to properly open, secure and close the vehicle lift doors, to activate any auxiliary interlock (if equipped), to load and unload the wheel- chair passenger (or standee) on and off the lift plat- form, and to property activate all lift functions. In event of power or equipment failure, refer to the Manual Operating Instructions section. Handrails and Outer Barrier The folding handrails and tall outer barrier are manually operated. The spring-loaded outer barrier (tall barrier) and the handrails rest on the platform when the lift is not in use. The outer barrier must be raised to the vertical position and the handrails must be lifted to the vertical position whenever a passenger is on the plat- form. The tall outer barrier and the handrails must be folded down to the platform (horizontal) position before stowing the lift. The handrails fold down onto the outer barrier to secure the barrier in the horizontal position. Each handrail is secured with a latch handle. The latch handle must be lifted before the handrails can be fold- ed or unfolded and must be lowered after folding or un- folding the handrails. Interlocking Handrail Belt The lift is equipped with an interlocking handrail belt. Once the lift platform has extended fully from the stowed position, the belt must be latched in order to raise or lower the platform. During the stow function, the belt must be unfastened after the platform raises or lowers to stow level and stops. With the belt unlatched, pressing the STOW switch then retracts the platform fully. ! . . Whenever a passenger is on the platform the: •Passenger must be positioned fully inside yellow boundaries. • Wheelchair brakes must be locked. • Inner roll stop and outer barrier must be up. • Handrail belt must be latched. Failure to do so may result in serious bodily injury and/or property damage. Copyright 2013 - Motor Coach Industries Int'I, Inc. and Its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Up From the stowed position, pressing the UP switch deploys (extends) the platform fully. The handrail belt must then be latched before the platform will raise. With the belt latched, pressing the UP switch then rais- es the platform to floor level height. Lift the handrail latch handles and lift the handrails to the vertical posi- tion. Lower the latch handle after each handrail is raised. Lift the outer barrier to the vertical position and latch the handrail belt. Press the UP switch until the platform stops (raises to floor level) and the inner roll stop unfolds to floor level. From ground level, the UP function will first automatically raise (rotate) the outer barriers to the upright (vertical) position. The platform then rises to floor level position. NOTICE The lift will not rise if the outer barrier is not in the UP position or the handrail belt is not latched (built-in safety features). Down The DOWN function lowers the platform to ground level and then unfolds the outer barriers to the ramp (horizontal) position. NOTICE The handrail belt must be latched to activate the DOWN function. From the stowed position, the lift will extend fully and stop. The handrail belt must then be latched before the platform will lower. Stow When the STOW switch is pressed, the platform first raises or lowers to stow level, stars to retract, and then stops. The handrail belt must then be unlatched before the platform will stow (retract) fully. The tall out- er barrier and the handrails must be folded down to the platform (horizontal) position before stowing (retract- ing) the platform. The handrail latch handles must be lowered before stowing the platform also. If any of these functions do not occur as described, discontinue lift use immediately and contact your sales representative or call The Braun Corporation at 1 -800 -THE LIFT. One of our national Product Support representatives will direct you to an authorized service repairman who will inspect your lift. Open Door(s) and Secure To Deploy Platform 1. Stand clear and press the UP switch until the platform extends fully. Release switch. 2. Lift handrail latch handles, deploy (lift) hand- rails up to vertical position, and lower hand- rail latch handles fully. 3. Lift outer barrier to vertical position. 4. Latch handrail belt. 5. Press the UP switch until the platform stops (raises to floor level) and inner roll stop un- folds to floor level. Release switch. To Unload Passenger NOTICE Passenger must be positioned fully inside yellow boundaries, outer barrier must be UP and handrail belt must be latched. 1. Load passenger onto platform and lock wheelchair brakes. 2. Press DOWN switch until the entire platform reaches ground level and the outer barrier unfolds fully (ramp position). Release switch. 3. Unlatch handrail belt, unlock wheelchair brakes, and unload passenger from plat- form. NOTICE Outer barrier must be fully unfolded (ramp position) until the entire wheelchair (or standee) has crossed the outer barrier. Copyright 2013 - Motor Coach Industries Inrl, Inc. and its subsidiaries. All Rights Reserved, P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August 2013 9 Page 22B-6 D Series Maintenance Manual ReliabiWty Driven Control Switch Functions NOTICE Door The lift will not stow with weight on the platform The lift can be interfaced for fully automatic opera- (built-in safety feature). tion of the power door system. Press the DOOR switch to open and close door(s) if applicable. NOTICE Up From the stowed position, pressing the UP switch deploys (extends) the platform fully. The handrail belt must then be latched before the platform will raise. With the belt latched, pressing the UP switch then rais- es the platform to floor level height. Lift the handrail latch handles and lift the handrails to the vertical posi- tion. Lower the latch handle after each handrail is raised. Lift the outer barrier to the vertical position and latch the handrail belt. Press the UP switch until the platform stops (raises to floor level) and the inner roll stop unfolds to floor level. From ground level, the UP function will first automatically raise (rotate) the outer barriers to the upright (vertical) position. The platform then rises to floor level position. NOTICE The lift will not rise if the outer barrier is not in the UP position or the handrail belt is not latched (built-in safety features). Down The DOWN function lowers the platform to ground level and then unfolds the outer barriers to the ramp (horizontal) position. NOTICE The handrail belt must be latched to activate the DOWN function. From the stowed position, the lift will extend fully and stop. The handrail belt must then be latched before the platform will lower. Stow When the STOW switch is pressed, the platform first raises or lowers to stow level, stars to retract, and then stops. The handrail belt must then be unlatched before the platform will stow (retract) fully. The tall out- er barrier and the handrails must be folded down to the platform (horizontal) position before stowing (retract- ing) the platform. The handrail latch handles must be lowered before stowing the platform also. If any of these functions do not occur as described, discontinue lift use immediately and contact your sales representative or call The Braun Corporation at 1 -800 -THE LIFT. One of our national Product Support representatives will direct you to an authorized service repairman who will inspect your lift. Open Door(s) and Secure To Deploy Platform 1. Stand clear and press the UP switch until the platform extends fully. Release switch. 2. Lift handrail latch handles, deploy (lift) hand- rails up to vertical position, and lower hand- rail latch handles fully. 3. Lift outer barrier to vertical position. 4. Latch handrail belt. 5. Press the UP switch until the platform stops (raises to floor level) and inner roll stop un- folds to floor level. Release switch. To Unload Passenger NOTICE Passenger must be positioned fully inside yellow boundaries, outer barrier must be UP and handrail belt must be latched. 1. Load passenger onto platform and lock wheelchair brakes. 2. Press DOWN switch until the entire platform reaches ground level and the outer barrier unfolds fully (ramp position). Release switch. 3. Unlatch handrail belt, unlock wheelchair brakes, and unload passenger from plat- form. NOTICE Outer barrier must be fully unfolded (ramp position) until the entire wheelchair (or standee) has crossed the outer barrier. Copyright 2013 - Motor Coach Industries Inrl, Inc. and its subsidiaries. All Rights Reserved, P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August 2013 DrivenD Series Maintenance Manual Page 22a-7 To Load Passenger NOTICE Outer barrier must be fully unfolded (ramp position) until the entire wheelchair (or standee) has crossed the outer barrier. NOTICE Passenger must be positioned fully inside yellow boundaries. 1. Load passenger onto platform, lock wheelchair brakes, and latch handrail belt. 2. Press UP switch to fold outer barrier UP fully (vertical), raise the platform to floor level, and unfold inner roll stop to floor level. Re- lease switch. 3. Unlock wheelchair brakes and unload pas- senger from platform. To Stow Platform 1. Latch handrail belt. 2. Press STOW switch until platform stops at stow level. Release switch. 3. Unlatch handrail belt. 4. Fold outer barrier down to platform (horizon- tal) position. 5. Lift handrail latch handles, stow (fold) hand- rails down to platform (horizontal) position, and lower handrail Patch handles fully. 6. Press STOW switch until platform stops (re- tracts fully). Release switch. CLOSE DOOR(S). Manual Operating Instructions In event of power or equipment failure, refer to the Manual Operating Instructions to manually operate the lift. Refer to the Lift Operating Instructions for all normal lift operation procedures (such as loading and unload- ing passengers). Follow all Lift Operation Safety Pre- cautions at all times. Cable -Activated Platform Manual Release System A cable -activated manual release system releases and engages the platform carriage assembly drive chain to allow the platform carriage assembly to be manually moved out (extended) or moved in (retracted) as needed. A T -handle Is provided on the release cable for ac- tivation of the manual release system (details follow). After manually moving the platform in or out, it is ex- tremely important that the cable -activated manual re- lease is positively re-engaged to secure (lock) the plat- form carriage assembly before loading a passenger on the platform or before driving the vehicle. Grasp the outer barrier and move the platform in and out until the platform locks (chain release assem- bly engages), securing the platform carriage assembly within the housing. You will feel the release mechanism engage. Failure to manually lock the platform carriage assembly (re-engage the carriage assembly drive chain) after manual deployment will allow the platform to roll in or out of housing unhindered during vehicle movement. Failure to lock the platform will also allow the platform to roll in or out of housing unhindered during hand pump raising and lowering procedures. After manually releasing platform, push manual re- lease T -handle in fully and ensure platform is locked before driving lift vehicle. Uncontrolled and unintention- al platform deployment (inadvertent platform ejection) may result in serious bodily injury and/or property dam- age. NOTICE The lift platform must be pushed back into its carriage compartment all the way before reverting back to normal (powered) operation. When the lift is fully extended manually, it does not activate the proper switches for normal operation. Returning (moving) the lift in fully allows for proper switch activation. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PM 03-26-0218 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August 2013 Page 22B-6 D Series Maintenance Manual f Push T -handle in fully and manually move platform in and out to engage platform lock before driving vehicle. Failure to lock platform may result in unintended platform deployment. Unintended platform deployment may result in serious bodily injury and/or property damage. Manual Operating Instructions 3759 Figure 3. Out (To Extend Platform) 1. Pull T -Handle. 2. Turn T -Handle to tock platform in released position. 3. Pull platform out. 4. Turn T -Handle. 5. Push T -Handle in. 6. Turn T -Handle to lock platform in engaged position. a I I 43764 Figure 4. Down (To Unfold Outer Barrier) Item Component 1 Platform 2 Actuator 3 Hairpin Cotter 4 Detent Pin 5 Outer Barrier 1. Remove hairpin cotter from detent pin. 2. Remove detent pin. 3. Unfold (rotate) barrier down. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PSN 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC D Series Maintenance Manual 43764 Figure 5. Up (To Fold Outer Barrier) Item Component 1 Platform 2 Actuator 3 Hairpin Cotter 4 Detent Pin 5 Outer Bamer t. Fold (rotate) barrier up. 2. Insert detent pin. 3. Insert hairpin cotter in detent pin. to Date August 2013 Page 22B-9 3759 Figure 6. In (To Stow Platform) 1. Raise or lower platform to stow level (follow UP or DOWN procedures). 2. Pull T -Handle. 3. Turn T -Handle to lock platform in released position. 4. Pull platform in. 5. Turn T -Handle. 6. Push T -Handle in. 7. Turn T -Handle to lock platform in engaged position. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PIN 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August 2013 Page 22B-10 D Series Maintenance Manual MAINTENANCE AND LUBRICATION Maintenance Indicator Proper maintenance is necessary to ensure safe, trouble free operation. Inspecting the lift for any wear, damage or other abnormal conditions should be a part of all transit agencies' daily service program. Simple in- spections can detect potential problems. The mainte- nance and lubrication procedures specified in the fol- lowing schedule must be performed by a Braun authorized service representative at the scheduled in- tervals according to the number of cycles. NHTSA NUVL Series lifts are equipped with a cycle counter (digital display built into the electronic control board). NUVL Series lifts are equipped with hardened pins and self-lubricating bushings to decrease wear, provide smooth operation, and extend the service life of the lift. When servicing the lift at the recommended inter- vals, inspection and lubrication procedures specified in the previous sections should be repeated. Clean the components and the surrounding area before applying lubricants. LPS2 General Purpose Penetrating Oil is recom- mended where Light Oil is called out. Use of improper lubricants can attract dirt or other contaminants which could result in wear or damage to the components. Platform components exposed to contaminants when lowered to the ground may require extra attention. Lift components requiring grease are lubricated during as- sembly procedures. When replacing these compo- nents, be sure to apply grease during installation pro- cedures. Specified lubricants are available from The Braun Corporation. All listed inspection, lubrication, and maintenance procedures should be repeated at 750 Cycle intervals following the scheduled 4500 Cy- cles maintenance. These intervals are a general guide- line for scheduling maintenance procedures and will vary according to lift use and conditions. Lifts exposed to severe conditions (weather, environment, contami- nation, heavy usage, etc.) may require inspection and maintenance procedures to be performed more often than specified. I Maintenance and lubrication procedures must be preformed as specified by an authorized service technician. Failure to do so may result in serious bodily injury and/or property damage. A Lift Ready green LED is mounted on the hand- held pendant storage bracket. The green LED will change color to yellow after every 750 cycles. The yel- low LED will not affect the functions of the lift, but is a reminder to perform necessary maintenance and lubri- cation procedures. Once the lift has been serviced, press the CYCLE button (located below LCD display on the control board) until the Lift Ready LED changes back to green. The CYCLE button also clears the lift cycle count (since last service) but not the lifetime cy- cle count. Discontinue lift use immediately if maintenance and lubrication procedures are not properly performed, or if there is any sign of wear, damage, or improper op- eration. Contact your sales representative or call The Braun Corporation at 1.800 -THE LIFT. One of our na- tional Product Support representatives will direct you to an authorized service technician who will inspect your lift. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Driven Lubrication Diagram D Series Maintenance Manual Date Page Figure 7. Lubrication Diagram August 2013 228-11 43761 Item Component Item component 1 Torque Tube Pivot Points 11 Inner Roll Stop Linkage Pivot Points 2 Lifting Arm Pivot Points 12 Lifting Arte Pivot Points 3 Rolling Horizontal Carriage Tube 13 Torque Tube Pivot Points 4 Eccentric Shaft and Carriage Rollers 14 Hydraulic Cylinder Pivot Points 5 Outer Barrier Pivot Points (Tall) 15 Drive Chain and Rollers 6 Outer Barrier Detent Pin 16 Drive Train Release Latch 7 Outer Barrier Pivot Point (Short) 17 Hydraulic Cylinder Pivot Points 6 Lower Closure Pivot Points 16 Eccentric Shaft Rollers 9 Eccentric Shaft and Carriage Rollers 19 Platform Manual Release Cable 10 Inner Roll Stop Hinge Pivot Points and Inner Roll Stop Catch Copyright 2013 - Motor Coach Industries Intl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August 2013 Page 22e-12 D Series Maintenance Manual Copyright 2013 — Motor Coach Industries InCI, Inc and its subsidiaries. All Rights Reserved. PIN 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Specified Lubricant Type (Recommended) Available Amount Lubricant Lo -Light Oil Light Penetrating Oil (30 Weight or equivalent) 1PS2, General Purpose Penetrating Oil 11 oz Aerosol can DE - Door -Ease Stainless Stick Style (tube) Door -Ease Stick (tube) 1.68 oz SG - Synthetic Grease Synthetic Grease (Multipurpose) Mobitemp SCHC32 12.5 or Tube Outer barrier and lower closure pivot points (2). Apply Light Oil - See Lubrication Diagram. Outer barrier detent pin pivot points (2). Apply Light Oil - See Lubrication Diagram. Inner roll stop hinge pivot points. Apply Light Oil - See Lubrication Diagram. Inner roll stop linkage pivot points. Apply Light Oil - See LubricationDiagram. Lifting arm center and platform pivot points Apply LightOil -See Lubrication (bearings at all pants). Diagram. inspect outer barrier and lower closure for proper operation. Correct or replace damaged parts. Inspect outer barrier seal and tower closure Resacure, replace, or correct as gasket. needed. Ensure hairpin cotter is present and Inspect outer bonier detent pin hairpin cotter. can be removed and inserted easily. Resecure, replace, or correct as needed. 750 Cycles Inspect lift for wear, damage, or any abnormal condition. Correct as needed. Inspect lift for rattles. Correct as needed. Pull out and lock manual release Check drive chain tension. cable. Adjust chain tension as needed. Inspect Neter roll slop (bridge plate) and linkage for proper operation. Roll stop should rest solidly on floor providing smooth transition. • Positive securement Resecure, replace, or correct as needed. • Wear or damage Check carriage ride height in housing Adjust as needed Lifting arms should be horizontal, Check slow heightAifting arm alignment. aligned with each other and aligned with carriage. Adjust a i needed. Inspect wiring harnesses for securement, wear, Resecure, replace, or correct as or other damage. needed. Check lower pan securement. Resecure, replace damaged parts, or correct as needed. Torque tube pivot bearings (4 places). Apply Light Oil - See Lubrication Diagram. Copyright 2013 — Motor Coach Industries InCI, Inc and its subsidiaries. All Rights Reserved. PIN 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. W D Series Maintenance Manual D iven Date August 2013 Page 22B-13 Copyright 2013 - Motor Coach Industries Infl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Specified Lubricant Type (Recommended) Available Amount Lubricant Carriage and eccentric shall rollers (bearings) Apply Light Oil -See Lubrication Diagram. Apply Door Ease - See Lubrication Lifting arm slots in rolling horizontal carriage Diagram. Apply to the surface area arm tubes. around both slots and wipe off excess. Hydraulic cylinder pivot points (4 per cylinder). Apply Light Oil -See Lubrication Diagram. Drive chain and chain rollers. Apply Light Oil - See Lubrication Diagram. Drive chain release latch mechanism. Apply synthetic grease - See Lubrication Diagram. Use compressor and nozzle to Deploy lift, remove inboard and outboard lower remove all debris from housing. pans, and blow out housing. Blow off platform Clean outboard lower pan slot and also, apply antiseize to slot before reinstalling pan. Use clean cloth and solvent to clean Deploy lift, remove inboard and outboard lower tracks. Clean lower pan slot and pans, and clean housing tracks. apply antiseize to slot before reinstalling pan. Check drive chain tensioner, jam nuts, and Check drive chain tensioner, jam 1500 Cycles Y connecting link for securement and/or misali nmem. nuts, and connecting link for securement and/or misalignment. Inspect drive chain release latch mechanism for proper operation, positive securement, wear, or other damage. Correct or replace damaged parts and/or relubricate. Ensure T -handle release and cable inspect ptattonn cable -activated manual assembly operate properly (see release system (T-handle/cable assembly and Manual Operation). Ensure carriage carriage movement). can be manually extended and retracted freely. Inspect gmit switches for securement and Resecure, replace, or adjust as proper adjustment. needed. Inspect carriage, Iiffing arm and eccentric shaft rollers (bearings) for wear or damage, positive securement, and proper operation. Correct, replace damaged parts, and/ or relubricate. Inspect external snap rings (e-c(ips): • Carriage roller bearings (4) • Lower lifting arm pins (5) • Upper lifting arm pins (2) Resecure, replace, or correct as needed. • Outer race bearings (2) • Inner roil stop shaft (2) Inspect lower lifting firm pins for wear or damage, positive securement, and proper adjustment. Resecure, replace damaged parts, lubricate, or correct as needed. Copyright 2013 - Motor Coach Industries Infl, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August 2013 Page 226-14 D Series Maintenance Manual Reliability Driven Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Specified Lubricant Type (Recommended) Available Amount Lubricant Inspect eccentric shaft pins, bearing mounting screw, washers, and securement hardware for Resecure, replace damaged parts, wear or damage, positive securement, and lubricate, or correct as needed. proper operation. Inspect torque tube cams for securement, wear, Resecure, replace, or correct as 1500 Cycles or damage. needed. Inspect housing cam brackets for securement, Resecure, replace, or correct as wear, or damage. needed. Inspect cylinder(s), hoses, liftings, and hydraulic connections for wear, damage, or Tighten, repair, or replace if needed. leaks. Inspect power cable. Tighten, repair, or replace if needed Hydraulic Fluid (Pump) - Check level. Use 5606 aviation fluid only. Check NOTE: Fluid should be changed if there is fluid level with platform lowered visible contamination. Inspect the hydraulic fully. FII to within 1-1/2 in. (36.1 mm) system (cylinder, hoses, finings, seals, etc.) for of the bottom of the fill tube (neck). leaks if fluid level is low. Inspect lifting arm bushings and pivot pins for visible wear or damage. Replace fl needed. Inspect outer barrier pivot pin mounting bolls (2) Tighten or replace if needed. 4500 Cycles Check to see that the lift is securely Mounting anchored to the vehicle and Mere are no loose bolts, broken welds, or stress fractures. Replace decals if wom, missing, or Decals and Antiskid illegible. Replace antiskid if worn or missing. Consecutive Repeat all previously listed inspection, 750 Cycle lubrication, and maintenance procedures at Intervals 750 cycle intervals. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August 2013 edven D Series Maintenance Manual Page 226-16 Safety interlock System The wheelchair lift safety interlock system prevents unsafe and unauthorized lift operation. The wheelchair lift will not operate unless the following conditions are met, in the following order: 1. The coach must be running. 2. The transmission must be in neutral. 3. The parking brake must be applied. 4. The master switch must be on. At this point, the interlock system disables the transmission shift and throttle, sets the park brake sole- noid, and begins engine fast idle. The interlock circuit also activates the telltale, hazard lights, audible alar, A and the wheelchair lift boarding area lights. 5. The lift cassette door must be open. 6. The secondary switch must be on. 7. The wheelchair lift safety belt must be buck- led. 8. The appropriate sliding door/wheelchair lift interaction must be met: To raise the lift, the sliding door must be closed until the lift reaches its automatic -stop posi- tion, approximately 9 in.. (228.6 mm) from the sliding door. Then, the door must be fully open to enable the lift to rise the remaining distance to floor level. To lower the lift, the sliding door must be open until the lift reaches its automatic -stop position, approximately 9 in. (228.6 mm) from the sliding door. Then, the door must be fully closed to enable the lift to lower the remain- ing distance to stow height. To open the sliding door, the lift must be positioned approximately 9 in. (228.6 mm) from the sliding door. Opening is a combination of manual and automatic movement. CAUTION If the lift is not positioned correctly, the motor will not engage. It is extremely important to fully close and latch the sliding door before resuming travel. If the door slides open, the parking brake will still be applied. To close the sliding door, the lift must be positioned approximately 9 in. (228.6 mm) from the sliding door. Closing is a combination of manual, automatic and manual movement. If the lift is not posi- tioned correctly, the motor will not engage. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August2013 Page 22B-16 D Series Maintenance Manual Reliability Ddverf TROUBLESHOOTING Function Possihls Cause Remedy Low Battery Check vehicle battery. Hydraulic Down Valve Open Check for good ground between Bad Ground vehicle chassis and 3/8 in. bolt on Pump Runs But Not Lift Platform Pump Mounted Horizontal back of power pack. Poor Plug Connections Check all plugs for proper contact. No Operation Blown Fuse Check all plugs for proper contact. Check fuses on printed circuit No Oil (Low) platform lowered fully. Fill to within 1-1/2 in. (38.1 mm) of the bottom of board. Circuit Sentry Reset circuit breaker. Check for voltage on red wire with Defective Interlock grey stripes in interlock plug connected to printed circuit board. Function Possible Cause Remedy Flush valve by operating up and Hydraulic Down Valve Open down manual override switches at same time for 4 to 5 seconds several times. Pump Runs But Not Lift Platform Pump Mounted Horizontal Power pack must be mounted Check level. Use 5606 aviation Cheheckk fluid fluid only. Check Fluid level with No Oil (Low) platform lowered fully. Fill to within 1-1/2 in. (38.1 mm) of the bottom of the fill tube (neck). Function possible Cause Remedy Pump Does NotUp Solenoid heck for power on pump black Run With wire going from solenoid to motor. Override Switch Or Hand-held Bad Power and Ground See No Operation. Pendant Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PIN 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. D Series Maintenance Manual Function I Possible Cause Lift Will Go Up Adjustment or Defective With Override Full Out Switch Is Not Activated or Switch But Not Defective With Hand-held Or Defective Pendant Hand-held Pendant Not Working Hydraulic Down Valve Bad y Properly Date August 2013 Page 22B-17 Remedy Check diagnostic LCD for Outer Barrier switch status. Adjust or replace switch as necessary. Check diagnostic LCD for Full Out switch status. Adjust or replace switch as necessary. Check for hand-held pendant illumination and contirwity of the switches. Verify SW 1 and Door Open switches are functioning correctly. Function Possible Cause Remedy Lift Will Not Go Poor Plug Connections Check for power on red valve wire from printed Down With Or Defective circuit board to Down solenoid when pushing Override Switch Hydraulic Down Valve Bad y override switch or hand-held pendant button. or With Hard- Calibration Replace If necessary. held Pendant, Bad Power and Ground Flush valve by operating up and down manual Goes Down Dirty Down Valve (Clogged) override switches at same time for 4 to 5 seconds Slowly or Drifts Detective several times. Down by Itself I Belt must be latched until platform is at stow level Function Possible Cause Full Out Switch Out Of Adjustm, Lift Will Go Down Defective With Override But SWO and/or Door Full Closed Not With Hand- Switches Out Of Adjustment or Hand- held Pendant Defective Remedy or replace switch as necessary. switches for proper operation/adjustment. or replace switch as necessary. Function Possible Cause Remedy ill Will of Poor Plug Connections Check harness connections Al. A2, B1, and B2. idend With Or Defective Check power at motor. Replace motor if )verride or Bad In/Out Motor necessary. land -held Calibration Sense Calibration. 'endant Bad Power and Ground See No Operation. Function Possible Cause Remedy Stow Level Switch Out OAdm Check diagnostic LCD for Stow Level switch Or Defective status. Adjust or replace switch as necessary. Platform Is Occupied or Out Of Remove weight from platform. See Platform Lift Will Not Stow Calibration Sense Calibration. With Hand-held SWO And/Or Door Full Closed Check switches for proper operation/adjustment. Pendant Switches Out Of Adjustment or Adjust or replace switch as necessary. Detective Belt must be latched until platform is at stow level Handrail Belt and must be unlatched before platform will stow. Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC Date August 2013 Page 2213-18 D Series Maintenance Manual RetfobiMy DMerr Function Possible Cause Remedy Barrier Will Not Check harness connectors Al, A2, El, Ni, N2, Operate Up or Poor Plug Connections F7, and F2. Down with Check power at motor. Slightly lengthen rod end Override Barrier Actuator Motor Or Actuator R release pin is difficult to remove or replace Switches or Out Of Adjustment or Faulty actuator if necessary. Hand-held Pendant Bad Power and Ground See No Operation. Function I Possible Cause Remedy ier Operates Faulty Outer Banier Switch Override ch But Will Barrier Occupied Go Up With d -held Handrail Belt Unlatched or Faulty Connections. status. Adjust or replace switch as necessary Remove weight from barrier. See Barrier Occupied Calibration. Latch handrail belt. Check connectors F1, F2, N7, and N2. Function Possible Cause Remedy h Pressure Transducer. Adjust or replace as Barrier Operates Faulty Pressure Transducer ty necessary. See Ground Sense Calibration. with Override Check diagnostic LCD for Below Stow Level Switch But Will Below Stow Level Switch Out Of switch status. Adjust or replace switch as Not Go Up With Adjustment or Defective necessary. Hand-held Pendant Full Out Switch Out Of Adjustment or Check diagnostic LCD for Full Out switch status. Defective Adjust or replace switch as necessary. Function I Possible Cause I Remedy No Power Going To Switches 1_'a' and 2. Switches Do NotI Faulty Wiring Change State in Diagnostic Mode [Faulty Connections of wires connector A2. Check for proper connections on each switch and on each connector on the harness. Replace contact it necessary. Copyright 2013 — Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC W D Series Maintenance Manual Driven CONTACT REMOVAL W Figure S. Contact Removal 1. Remove orange wedge using needle nose pliers or a hook shaped wire to pull wedge straight out. 2. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver. 3. Hold the rear seal in place, as removing the contact will displace the seal. CALIBRATION Calibration Procedures Pfaff orm Sense Calibration 1. There must be no weight on platform. 2. Press hand held -pendant UP switch to raise platform a minimum 3 in. (76.2 mm) above stow level. 3. Press and hold control board mounted 50# CAL button. While pressing the 50# CAL button, press and hold the hand-held pen- dant STOW switch (button). The platform will lower to stow level (begin stow function), and then start to raise. Release 50# CAL button immediately when platform starts to raise from stow level. 4. After calibration, the LCD screen should read PF OCCUPIED whenever there are 50 this (23 kg) or more present on the plat- form. Date August 2013 Page 22B-19 11339 Ground Sense Calibration 1. Press hand-held pendant DOWN switch to lower platform fully to ground level. 2. While continuing to press the pendant DOWN switch, press and then release con - bol board mounted O_BAR button. 3. Release the pendant DOWN switch. 4. After calibration, the LCD screen should read GNO LVL 1 (in diagnostic mode) when- ever the platform is at ground level. Outer Barrier Occupied Calibration 1. Press hand-held pendant DOWN switch to lower platform fully to ground level. 2. Once outer barrier is fully unfolded (ramp position), release the pendant DOWN switch. 3. Press and hold the control board mounted O_BAR button. While holding O_BAR but- ton, press handheld pendant UP switch to raise the outer barrier. Be sure to release O BAR button when outer barrier reaches approximately half full up (vertical) position. 4. After calibration, the LCD screen should read OUTBAR OCCUPIED whenever there is weight present on the outer barrier. Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. Al Rights Reserved. P/N 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. Date August 2013 Page 22B-20 D Series Maintenance Manual NHTSA OPERATIONS CHECKLIST The following operations have been verified upon installation. This operational checklist ran be used at any time to verify the lift is fully functional. Verified: • Vehicle movement is prevented unless the lift door is closed, ensuring the lift is stowed. • Lift operation shall be prevented unless the vehicle is stopped and vehicle move- ment is prevented. • The platform will not fold/stow If occu- pied. • The inner roll stop will not rise if occu- pied. • Verify platform lighting when lift is deployed and pendant illumination when lift is powered. DESCRIPTION • The outer barrier will not rise if occu- pied. • A visual and audible warning will acti- vate if the threshold area is occupied when the platform is at least 1 in. (25 mm) below floor level. • Platform movement is prohibited beyond the position where the inner roll stop is fully deployed (up). • Lift platform movement shall be inter- rupted unless the outer barrier is deployed (up). 1 Discontinue lift use immediately if any lift or vehicle Interlock does not operate properly. Failure to do so may result in serious bodily injury and/or property damage. SPECIFICATIONS Manufacturer..... .............. ...... ServiceManual ...................... . _...... _...._ _............. _....... _................ Voltage.... ................... . ....... . . . .. ................ .............. _............. NUVL855RM24 .............24 VDC Copyright 2013 - Motor Coach Industries Int'I, Inc. and its subsidiaries. All Rights Reserved. PIN 03-26-0219 CONFIDENTIAL INFORMATION OF MOTOR COACH INDUSTRIES INTERNATIONAL, INC. F VIEW REFERENCE VIEW Qs VIEW A SEC71 N 8 DETn IL 1 ur+.E i..TIN 'w i— — wren. . Tv{ 03.1 ..)9 RR rrE RE.IN tl11RF0 SE./.' 1 V.vUrr mnM'w. � �NIII S n •rrw°.�:DO.TIX.NGII. ®Fl s�EeINII, 1. rME`".�r'".zI l+ol °.uR.Eo IN r:c g�.r w�. w wN-II-5..- f, L®. M S�°d:. lM Of>�pplEyy. iB 3vU�t30 Wv R OIfrEEE9in�Fgr.5 WRMIsv .Ok' �g ...W RFi:M 1. Sr1IF1 . NEEC°d44M Ilut Mlq 03-11-1898 J m•Es. dSATE ME EI ro IW EI m.I I-I.? PEF TAL ASTS,P ° gnr IATTLI 21 MALI TxE L.iA.,. x .vn E WY 1rE ;EAT IN IISS TS P�Ir eW'Sn4i �°M. WrciILEMATW C'', P ISIll n 1116' CIA w.c AT TILE LECATIp5 ..,S. ^ExRAE° w TNS SEAT TPAT, NPWPEWO ITS i°O: saaW Gq+Rlnw.�p'�O�aiBEif;�tAs6ATK w�r� �xIS TK ryY w PIryR STT rutAe T.E 1E Ano I YI IS NS MO x rK SEAT��zz--- r A. ILL Pvsl l i INS - PlnAxOPLEoE4ESTnl'MOw LL ivii" pfT�rvFSLOCM IIKAi� S. .IOEE S��M; Ell. r'Gw lice TPM( Y!0.1L TT AOibTE. WIT 1L S T yGvrpMv noE ovx:' NE'f:"'IAAxIxSP I- STILL KTA]vE nxv $En• MTitF TrCx E%InC(.t. LK SANDE YAT 0E 0- D SO TxE •F4G4MY LCIX wY 91 — MT ®1,A45 . Y — Z E1� [x I TI( WE,kT. EANEW. T-1 A. .11.1N I AT AN AII.,ASENI IASET SE PD TTTW° MSE °iuEE' R6" sTAILIT i':s ¢i"IT Iix �I�Mi. EW A CETAIL I SGLfi 1 2 VIEW A 03-11-1503 �•re .oe�r..a o-.�Imcw.rz:z - 1 Reliability Driven" ATTACHMENT L DIAGRAM AND INFORMATION ON PROPOSED SEATING An TAmrT ' ,ll,a\111,11111111- .,.1,1,111.1 „ 111 I, 1111,,,11111111111 .,111 „ 1/11111111 „ ,1,111111,111,111111 ,,.11.,,11111111111, 111111111,111111, 111 I ,1f1,11, 111, 11, ,, 111 ,, 111. f 11, r,1,11 .1,1 ,,,1,11.1.1,1111.,.,1 ,111,•\,,.,,,,111.,, 1111,1 „ 11,1111,1111„1,11 .,i„1,1„I.a, 1, 1.1„1 �\111\11111111111111, ,,,;,,,;,,;,,,,,,,, „\.,,,\,,,,\„11111.• ,\\111 11,„11111 1 1 1111.11 11 1 1.1 Ir11 Old IIre FEATURES • The "Torino Transit" seat has been developed with a thin high backrest providing extra hip -to -knee room and includes the well known ergonomic design provided in all the Amaya-Astron seat models. • Fold down aisle armrest. • Stationary window armrest. • Mechanical recliner mechanism. • The frame incorporates steel tube box construction and steel interior back plate, all metal components are powder coated. • Cushion, back and headrest made from fire retardant and high resilient polyurethane foam. • Cord carpet on the back of the seat. • Steel powder mated pedestal. • The "Torino Transir seat can be installed in 96" and 102" coaches. OPTIONS • Square type grab handle mounted on top of backrest. • Round type grab handle mounted on top of backrest. • Classic type grab handle mounted on aisle side of backrest. • Plastic manual footrest, "Boomer' model. • Sliding and stationary gip up seats for handicap seating configuration. Torino Transit /AMAVA OW iiii� rr� a=:m_ MEXICO SMALL & MEDIUM BUS SALES RoEwto Fulton e, Fraceionav,bnto Ind. fan W-1.9 lbWn ntb. Estado de Meaice. SQU Plw .55(55)5)11-6000 (M)W4.2 W tlmwan@aarmtoaemaya,eanma infoWrc dU nsea0WXM www.FeednwnveabN.coin www.amaya-astron.com.mx FOR TRANSIT SALES 71kt v,wf (610) 2653610 Infocm..com ww.60NE.com Reliability Driverfm ATTACHMENT M SUSPENSION SUSPENSION The front and rear axle suspension shall be pneumatic and equipped with straight side lobe air suspension bellows. Four suspension bellows shall be provided on the drive axle and two suspension bellows on the front axle. The tag axle shall be equipped with two straight side lobe type air springs, 9.5 inch (241 mm) nominal in diameter. Pressure in the tag axle suspension shall be automatically adjusted as required by the load -sharing system. Manual air dump valves for unloading the tag axle air suspension bellows shall also be provided in the engine compartment. The basic suspension system exclusive of bellows, height control valves, bushings and shock absorbers, shall last the life of the coach without major overhaul or replacement. Four (4) heavy-duty rubber bushed silent block sleeve type radius rods shall be provided at both the front and rear drive axles to control lateral, longitudinal, and torsional movement. Radius rod bushings shall be Clevite or approved equal. One transverse stabilizing rod shall be provided on front axle for additional support during coach lane changing or turning of comers. The coach shall be equipped with a sway bar designed to reduce body lean and increase bushing life. Items such as bushings and air springs shall be easily and quickly replaceable. Adjustment points shall be minimized and shall not be subject to a loss of adjustment in service. Necessary adjustments shall be easily accomplished without removing or disconnecting the components. SPRINGS AND SHOCK ABSORBERS TRAVEL The suspension system shall permit a minimum wheel travel of 3.5 inches (89 mm) in jounce and 3 inches (76 mm) in rebound. Elastomeric bumpers shall be provided at the limit of jounce travel. Rebound travel may be limited by elastomeric bumpers or hydraulically within the shock absorbers. KNEELING A driver -actuated kneeling device shall lower the coach floor 3.0 to 6.0 inches during loading or unloading operations regardless of load to a floor height of 42 inches (1.07 m) measured at the longitudinal centerline of the front door. The park brake shall prevent movement when the coach is kneeled. The coach shall kneel and rise at a maximum rate of 1.5 inches per second at essentially a constant rate. A flashing indicator visible to the driver shall be illuminated until the coach is raised to a height adequate for safe street travel. An audible warning device that operates with the kneeling system shall be provided. A visual indicator meeting ADA requirements shall be provided on the curbside of the coach and shall activate during the kneeling operation. This indicator shall be appropriately marked and visible to the boarding passenger. DAMPING Vertical damping of the suspension system shall be accomplished by hydraulic shock absorbers mounted to the suspension arms or axles and attached to an appropriate location on the chassis. Damping shall be sufficient to control coach motion to 4 cycles or less after hitting road perturbations. Shock absorbers shall maintain their effectiveness for at least 50,000 miles (80,467 km) in normal service. The coach shall be equipped with four shock absorbers on the drive axle and two on each side of the front axle and one on each end of the tag. Shock absorbers shall be interchangeable on each axle, side to side. Reliability Driven" ATTACHMENT N CNG FUEL STORAGE INFORMATION Reliability Driverf FUEL SYSTEM DIESEL FUEL TANK An aluminum fuel tank shall be provided and securely mounted to the coach to prevent movement during coach maneuvers, and shall be easily removable for cleaning or replacement. Fuel tank capacity shall be 182 useable gallons. The fuel tank shall be equipped with an external, hex head, brass drain plug. The drain plug shall be at least 3/8 inch size and shall be located at the lowest point of the fuel tank. Access covers shall not be provided. The tank shall be baffled internally to prevent fuel sloshing noise regardless of fill level. Baffles shall run the full height and length of the tank. The baffles and fuel pickup location shall assure continuous full power operation on a 6 -percent upgrade for 15 minutes starting with no more than 25 gallons of fuel over the unusable amount in the tank. The fuel pickup tube shall be perforated and mounted to the bottom face of the tank to insure the pickup screen stays at the bottom of the tank. Fuel shall be drawn through the fuel tank pickup tube fitted with a screen that will prevent debris from entering the fuel line. The fuel tank shall have a permanently affixed plaque stating manufacturer, certification, capacity and date of manufacture. The plaque shall be clean and legible after the undercoating process, and shall comply with EPA requirements. The plaque shall be substantially visible when the fuel fill door is opened. A non -heated Fuel ProTm fuel filter shall also be provided. A clear cover will allow visual inspection of filter and fuel condition and fuel flow. FUEL FILLER The fuel filler shall be designed to fill the fuel tank to the fill point, shall automatically shut off when fueling is complete, and shall eliminate foaming and blow back. The filler cap shall be recessed into the body so that spilled fuel will not run onto the outside surface of the coach. The filler shall accommodate a fill rate of forty (40) gallons per minute of foam -free fuel without causing the nozzle to shut off before the tank is full. An audible signal shall indicate when the tank is essentially full. MOTOR COACH INDUSTRIES, INC CNG VEHICLE OVERVIEW 40 & 45 FOOT COMMUTER COACH uy{ O i 1� Y Y w Confidential Information of Motor Coach Industries, Inc. Fuel Storage • CNG TANKS — 3 preassembled tank modules • 9 tanks total: 15500 SCF total capacity — 4 tank module in front baggage compartment — 3 tank module above the wheel chair lift — 2 tank, fuel fill and control module in fuel tank compartment — Hose between tank modules — Tanks total weight 1300 lbs. (tanks only) — Diesel equivalent capacity -110 gallons approximately — End mount tanks with manual shutoff valves Confidential Information of Motor 6 Coach Industries, Inc. CNG tank system arrangement Confidential Information of Motor 7 Coach Industries, Inc. Baggage bay 1 CNG tank module 4 CNG tank module complete with PRD's and shutoff valves ; P, Confidential Information of Motor Coach Industries, Inc. U Baggage bay 2 CNG tank module • 4 CNG tank module complete with PRD's and shutoff valves Confidential Information of Motor Coach Industries, Inc. Fuel tank module • Fuel fill, defuel, regulator, engine shutdown etc. module Confidential Information of Motor Coach Industries, Inc. 10 Fuel FilkDefuel Panel • Fuel fill located in present diesel fuel fill location — Both slow fill and fast fill connections provided as standard" Confidential Information of Motor 11 Coach Industries, Inc. CNG System • Complies with NFPA 52 • Low fuel indicator — Actuates at 500 psi tank pressure • PRD vents plumbed to rear upper of the vehicle • AMEREX Safety net engine fire suppression and methane detection system Confidential Information of Motor 12 Coach Industries, Inc. Cummins Westport The ria;{.iri d {'Nc�ic; SX12 G Heavy -Duty Nati iral C as Truck Enaine The Natural Choice. ISM 2 G Heavy -Duty Natural Gas Truck Engine. The Cummins Westport ISX12 G natural gas engine delivers the strong pulling power and heavy-duty durability required for regional -haul truck/tractor, vocational and refuse applications. It features Stoichiometric cooled Exhaust Gas Recirculation (SEGR) combustion technology, which allows the use of a maintenance -free Three -Way Catalyst (TWC). Ratings range from 320 hp to 400 hp (239-298 kW) with 1450 lb - (1966 N -m) of peak torque. The inherent efficiency of this engine and an abundant supply of natural gas reduce operating costs, making the ISX12 G the natural choice for your fleet. Dedicated Factory -Built Natural Gas Engine. The ISX12 G is a dedicated, factory -built natural gas engine that is based on the Cummins ISX12 diesel engine. The ISX12 G shares many of the same parts and components as its diesel counterpart, and it operates on 100 percent clean -burning, low-cost natural gas. The ISX12 G meets current U.S. Environmental Protection Agency (EPA) and California Air Resource Board (ARB) emissions standards, and 2014 EPA greenhouse gas (GHG) and U.S. Department of Transportation (DOT) fuel - economy regulations. The ISX12 G is a great choice for mixer, dump truck and refuse applications, with a high power -to -weight ratio and 700 Ib -ft (949 N -m) of clutch engagement torque. Four refuse ratings, as well as Front Engine Power Take - Off (FEPTO) and Rear Engine Power Take -Off (REPTO) options, offer power and flexibility for a wide variety of vehicles. The ISX12 G is also the natural choice for regional -haul and LTL distribution operation trucks and tractors. Five ratings from 320 hp to 400 hp (239-298 kW), engine braking, and manual or automatic transmission capability provide trucking customers with the performance to meet fleet requirements, and the flexibility of using either compressed natural gas (CNG) or liquefied natural gas (LNG). Advanced Combustion Technology. The ISX12 G uses SEGR combustion with spark ignition to create a high-performance, heavy-duty natural gas engine. The cooled-EGR system takes a measured quantity of exhaust gas and passes it through a cooler to reduce temperatures before mixing it with fuel and the incoming air charge to the cylinder. SEGR results in improved power density and fuel economy versus traditional stoichiometric or lean -burn natural gas engines. This technology also enables the use of a TWC for emissions control. Maintenance -Free Aftertreatment. TWCs are effective, simple, passive devices packaged as part of the muffler. They provide consistent emissions control performance, are maintenance -free and can be mounted vertically or horizontally on the vehicle. The ISM 2 G requires no active aftertreatment such as a Diesel Particulate Filter (DPF) or Selective Catalytic Reduction (SCR). Natural Gas — The Fuel Choice Is Yours. The natural gas, G operates b car percent natural gas, which can be carried on the vehicle in either comnrnssed or liquefied 40101� form (CNG or LNG. respectively). The ISX12 G can also run on renewable natural gas (RING) made from biogas or la, 41110111111, gas that has been upgraded to vehicle fuel -quality. A variety of CNG and LNG tank configurations are available to meet range requirements. Consult your vehicle manufacturer for details. /SX12G Design Arcr 4.-"+ Wastegate Turbocharger 4 -Valve Cylinder Head 0 Scan the OR Code to vlew the ISX12 C, technology walkaround video. ^^il-On-Plug Ignition Features And Benefits. > Advanced Air Handling - Electronic control for precise air handling. > Proven Wastegate Turbocharger - A small -frame, fixed - geometry, wastegate-style turbocharger is used. A water- cooled bearing housing adds durability. > Engine Control Module (ECM) - Constantly monitors and controls engine sensors, fuel system and ignition system. Drive -by -wire throttle control. Provides OEM and end- users with the ability to tailor performance of the engine to fit the vehicle's mission. Full interface capability to Cummins INSITE'" and Cummins QuickCheck diagnostic service tools. - > High -Energy Ignition System - Provides better performance and longer service intervals, improved spark plug and coil durability and sell -diagnostics. The ignition module and fuel module are controlled by a full -authority CM2180A ECM with programmable features, which is compatible with Cummins diagnostic tools. EGR Valve — Fuel Module nergy Ignition System ntrol Module (ECM) > Accessory Belt Drive System - Seff-tensioning serpentine polyvee belt accessory drive system for water pump, engine -mounted fan hub and most alternators. > Air Intake System - Charge -air cooling reduces emissions by lowering intake manifold air temperatures. > High -Efficiency Lube Cooler - Lowers oil temperatures, for longer engine fife. > Crankshaft - The eight -counterweight, fully balanced. high -tensile -strength steel forging has induction -hardened fillets and journals, for outstanding durability. > Optional Engine Braking -240 hp (180 kW) at 2100 rpm. > Transmission -Automatic and manual options available. > Front- and Rear Engine Power Take -Off (FEPTO and REPTO) - Options provide additional torque, for a variety of vocational applications. ISX12 G Ratings Engine Advertised Model by (kW) Peak iorsue Governed lb-It(N•m) O rpm Speed Line Haul Track Applications ISX12 0 400 400 (298) 1450 (1988) O 1200 2100 RPM W12 G 386 385 (287) 1350 (1830) O 1200 2100 RPM ISX12 G 350 350 (261) 1450 (1966) O 1200 2100 RPM ISX12 G 330 330 (246) 1250 (1695) O 1200 2100 RPM ISX12 G 320 320 (239) 1150 (1559) O 1200 21 DO RPM Refuse Truck Applications mt121335011 350 (261) 1350 (1830) 01200 2100 RPM 1S12G350R 350 (261) 1450 (1966) 01200 2100 RPM 5X12 G 330R 330 (248) 1250 (1695) O 1200 2100 RPM 5X12 G 3208 320 (239) 1150 (1559) O 1200 2100 RPM ISX12 G Specifications Modmurn Horsepower 400 HP 298 kW 1450 LB -FT ,966 N -in ISX12 G Maintenance Intervals Peak Torque Governed Speed 2100 RPM Maintenance Item Mfles/l(ilometars Hours Months Clutch Engagement Torque 700 LB -FT 94g N -m Deily Check Spin -On Fuel Filter Type 4 -cycle, spark -ignited, In-line 6 -cylinder, Oil And Fiher' 18,000 MI 400 6 turbocharged, CAC 30,000 KM Engine Displacement 726.2 CU IN 11.9 LITERS Coolant Riter" 67,500 MI 1,500 12 Bore and Stroke 5.11 IN s 5.91 IN 130MM x150M M 108,500 KM Spin-On Fuel Fier' 45,000 MI 1,000 12 Operating Cycles 4 72,300 KM Oil System Capacity 12 U.S. GALLONS 45.4 LITERS Spade Plugs' 67,500 MI 1,500 12 Coolant Capacity 26.5 U.S. QUARTS 25.1 LITERS 108,500 KM System Voltage 12 V Ovemead 67,500 MI 1,500 12 Not Weight (Dry) 2,650 LB 1,202 KG Adjustment 108,500 KM Fuel Type CNG/LNG/RNG Engine Brake 270,000 MI 6,000 24 Aftertreatment Three-WaY CalalYst (IWC) Adjustment 435,000 KM Standard Coolant 270,000 MI 6,000 24 435,000 KM Air Cieaner/Elemen[ Follow vehicle manufacturers published recommendations •Assuming mmol duty arctePoeaeO on 45 mph P2.e kplq average speed Spark plug imervel ant overread adjuffiner t nasi tie reduced for slower speed apphcaeane. ^Do rnt &arge g SCA above 3. ^Requires natural gas argne oil fCES20074). > Intervals fpr ndmal duly - mg be mdumd for lower average spercWduly cycles ) Oahu t irnerval Is me rips, stated Interval -p v Older comes fnn - hours, mires or months. > Refer to Owners Msnual for compete deteee on mantenaca intervals. ISX12 G Torque Curves. M in0 1. 1M 14M 16U IM ilW TLW 104. spw Main With torque curves similar to those of the ISM 2 diesel within the 1150 lb -ft -to -1450 1b -ft (1559-1966 N -m) range, the ISX12 G offers comparable vehicle performance and drivability. rearing Recommendations. For best reliability and durability, the recommended maximum GVW for the ISM2 G in line -haul applications is 80,000 Ib (36,287 kg). Recommended gearing is 1400 rpm to 1450 rpm at cruise speed, to optimize fuel economy. Optimizing Performance With PowerSpec. Cummins PowerSpec helps you find the ideal gearing specs for engine performance cr fuel economy, making it possible to tailor the operation of Cummins Westport engines to fit every customer's application. PowerSpec can also read fault codes, and can be programmed to collect trip information for multiple drivers. PowerSpec works on both the ISL G and the ISX12 G. See powerspec.cummins.com for more information. ti Base Warranty. The automotive base warranty for the Cummins Westport ISX12 G natural "Al i1at�V gas engine is the same as for the Cummins diesel base platform. Base warranty covers 2 years/250,000 miles (402,336 km) and 100 percent parts and labor on warrantable failures." 'Wa„dnlapiB lypn65 dr. I.,o6G dl: f0 QelBCts n Cuf'.T::S mi1C,.1 P f 0 1 Y/W +I18nbt1i0 Extended Coverage. For additional peace of mind, Cummins Westport offers a variety of extended coverage plans to meet every customer's need. For details on extended coverage options, contact your local Cummins distributor or Cummins Westport representative. Better Customer Care. Cummins Westport -powered vehicles are supported by Cummins service network, the largest and most capable in North America. Cummins authorized technicians are fully trained on Cummins Westport natural gas engines, with ready access to Genuine Cummins Parts and warranty support. For questions regarding your Cummins Westport engine, or for assistance in finding a repair facility in the United States or Canada, call Cummins Care at 1 -800 -DIESELS - (1 -800-343-7357). Cummins Westport -The Natural Choice. Cummins Westport Inc. designs, engineers and markets 6- to 12 -liter spark -ignited natural gas engines for commercial transportation applications such as trucks and buses. Our dedicated 100 percent natural gas engines are manufactured by Cummins, and are available as a factory -direct option from leading truck and bus manufacturers. To learn more about Cummins Westport and natural gas as a transportation fuel, visit the Cummins Westport Natural Gas Academy for information, resources, videos and more - at cumminswestport.com/natural-gas-academy- Wst 75th Avenue, Vncouver, Canada V6P 6G2 50 Westport Pho e7504-7718-61 0 Fax 6048718 83558 nfofcummin westport.com cumminswestport.com Bulletin 4971420 PrintedinU.S.A. 3f13 02013 Cummins Westport Inc. Annual Fuel Savings Estimator Annual Fuel Consumption (values in DGE' (diesel gallon equivalent] per year per truck) Annual Fuel Savings (values in dollars per year per truck) Westp.,rt These tables are provided as a quick estimate of the potential fuel cost savings of a Cummins Westport powered natural gas vehicle, based on the difference in cost between diesel and natural gas (CNG or LNG), and the expected fuel economy, and annual miles (km) and resulting annual fuel consumption. DGE / DLE measures the volume of natural gas it takes to equal the energy content of a liquid gallon or litre of diesel. Annual Fuel Consumption (values n OLE' (diesel litre equiva. _ .er year per truck) Annual Fuel Savings (values In dollars per year per truck) Fuel Price Annual Fuel Consumption IDLE per year) Difference ., 15,000 io,000 20,000•• 60,000 80,000 100,000 120,000. ,,. 160,000 180,000 200.000 0.05 125 175 250 500 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 0.10 250 350 500 1,000 2,000 4,000 6.000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000 0.15 375 525 750 1,500 3,000 6,000 9,000 12,000 15,000 18,000 21,000 24,000 27,000 30,000 33,000 0.20 500 700 1,000 2,000 4,DW 8.000 12,000 16,000 20,000 24,000 28,000 32,000 36,000 40,000 44,000 0.25 625 875 1,250 2,500 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000 55,000 0.30 750 1,050 1,500 3,OW 6,000 12,000 18,000 24,000 30,000 36,000 42,000 48,000 54,000 60,000 66.000 0.35 875 1,225 1,750 3,500 7,000 14,000 21,000 28,000 35,000 42,000 49,000 56,000 63,000 70,000 77,000 0.40 1,000 1,400 2,000 4,000 8,000 16.000 24,000 32,000 40,000 48,000 56,000 64,000 72,000 80,000 88,000 0.45 1,125 1,575 2,250 4,500 9,000 18,000 27,000 36,000 45,000 54,000 63,000 72,000 81,000 90,000 99,000 0.50 1,250 1,750 2,500 5,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 110,000 0.55 1,375 1,926 2,750 5,5W 11,000 22,000 33,000 44,000 55,000 66,000 77,000 88,000 99,000 110,000 121,000 0.60 1,500 2,100 3,000 6,000 12,000 24,000 36,000 48,000 60,000 72,000 84,000 96,000 108,000 120,000 132,000 0.65 1,625 2,275 3,250 8,500 13,000 26,000 39,000 52,000 65,000 78,000 91,000 104,000 117,000 130,000 143,000 0.70 1,750 2,450 3,500 7,000 14,000 28,000 42,000 56,000 70,000 84,000 98,000 112,000 126,000 140,000 154,000 0.75 1,875 2,625 3,750 7,500 15,000 30,000 45,000 60,000 75,000 90,000 105,000 120,000 135,000 150,000 165,000 0.80 2,000 2.800 4,000 8,000 16,000 32,000 .48,000 64,000 80,000 96,000 112,000 128.000 144,000 00 160,0 176,000 =00=* FRONS OF COACH Reliability Driven" ATTACHMENT 0 MCI's proposal is based on providing the specification requirements as specified in the "request for proposals" technical documents except as noted on Certification No. 7 form for proposal deviation included with Attachment # 3 of our Technical Proposal. Additionally, we have also provided a list of available options with Attachment # 4 of our Price Proposal. Reliability Driven ATTACHMENT P Please find attached Carb Certification for the Cummins ISX diesel engine. Carb Certification for the Cummins ISX CNG engine has not yet been provided. MCI will provide the applicable Carb Certification once it becomes available. CUMMINS INC. Pursuant to the authority vested in the Air Resources Board by Health and Safety Code Division 26, Part 5, Chapter 2; and pursuant to the authority vested in the undersigned by Health and Safety Code Sections 39515 and 39516 and Executive Order 13-02-003; IT IS ORDERED AND RESOLVED: The engine and emission control systems produced by the manufacturer are certified as described below for use in on -road motor vehicles with a manufacturers GVWR over 14,000 pounds. Production engines shall be in all material respects the same as those for which certification is granted. MODEL ENGINE FUEL TYPE STANDARDS aTEST SERVIC€ ECS 6 SPECIAL FEATURES DIAGNOSTIC YEAR ENGINE FAMILY BIZES ILi Diesel PROCEDURE DLASS DDI, TC, CAC, ECM, EGR. CC, PTOX, SCR -U GBD(S) 2013 DCEXH0D7L[2.9XAF 71.9 Diesel UB PRIMARY 16 ADDITIONAL IDLE EMISSIONS CONTROL E EMISSIONS CONTROL Exempt N/A ENGINE ILI ENGINE MODELS I CODES (nte4 pcwv, In NPI 11,g ISX12 38513712;FR20434 (379) 11 PO=O01 • •npl applxedio. •praEE vaniw.a,711 rawq. •YR= aH 1 ¢nio ow epwMipne. amn m. ap a ,W ,yae rm Irons. m io y+Nd. RP`Mseporar kw•xilwalt. M,ro,m. aF=d tool, OF=BUY M1IaI FF=Bwle4!ud. CNWLNG•wmyaasedNPusfisa nio•.urd pn. LPG=seusfroe pendMvn per: F26•a5%aMena tool MF•muni Nei eMe y UMIN HDD=Ipn,imaelumawevy Mav(-0Ny tl,ioad. Vawror, w+s, Ono, -Nox aY olc r NAC!9WUIPYnxl" HAFS'h9nfNefgbl (eke uvaIDsse) TWCy(IC•weawM1Y aTsf m.Wlyirr DF1*#wlnWMerPTWIraPO 12SIOwiiWOrytsen l,Eme•ICddepxt,1.1 SFlIuR.I*VNK; Palumiry,., 001-d., n•lgdRB-9-EwmIDVDDIxudd 6nMix, TUSC.IWd o,mlw CAC=.i1..rwEGRIEGRCevWER5rMI,HIXWEGR PAIRIAIiyOwftKnryrvm, SF-siMKb0JWQCInM=apWx ,deptaerb. ,y pW 1211.Y411FYIn renes. . EMeanpineaaa, Z(pnePpYNbI. snl,pn; ALT=mamioevio mausoe EaBY,Nme Hxneovn anlam loan t3 CCR 1958 &aN6%ANII, �Pp•3D yM NOF W1 1CCR Ia56 BIaNBNC) APa =InronW dmeuamn eudrory ppAtl 11 CC0.1956.81aN8%81 d la CNG4NG AN vysums, NIfwM aPpiuds (e p_ Ouo arq.wa+�+aecAa*1. SPx 13 CCR 1654 e(a86%01. Exampnanmp+iotl iW Ayal ehdY,N roc:. EYD= rre men,tsaurerd R,c /3 CCR rp]t.0ap I P 13*1111 �t roma Following are: 1) the FTP exhaust emission standards, or family emission linnit(s) as applicable, under 13 CCR 1956.8; 2) the EURO and NTE limits under the applicable California exhaust emission standards and test procedures for heavy- duty diesel engines and vehicles (Test Procedures); and 3) the corresponding certification levels, for this engine family. 'Diesel" CO, EURO and NTE certification compliance may have been demonstrated by the manufacturer as provided under the applicable Test Procedures in lieu of testing (For flexible- and dual -fueled engines. the CERT values In brackets t l aro those when tested on jonventional tat fuel. For multi -fueled engines, the STD and CERT values for default operation permitted in 13 CCR 1956.8 are in parentheses.). in WHO NOR NMMCaNOr CO PM HCNO 9/bhp-hr FTP EURO FTP EURO FTP EURO FTP EURO FTP EURO FTP EURO STD 0.14 0,14 0.10 0.20 15.5 1 15.5 I 0.01 I 0.01 FEL 11 PO=O01 CERT 1 0.03 1 0.01 1 0.12 1 0.07 0.5 0.002 ' NTE 0.21 0.30 19.4 O.D2 ' yprys.hrplems per Msxe twneppwdi,w*'. FTP=FioM:N Tiosl Prv�+traio, EUAp=EuloM Ewawr SWMy-8nsio CYde. bKlu4m8 RIACSET=rmn nwaa cygio aupgen,m,liol 9,lnaTenE Wons NM."46Ex.,, STD=s1io,pMe ar em�seron WKaro. FEL=ramiy emWEien linpl; CERT=wean W+M', NMHCIHC=rgnm,Hnerrolnydowbcn, NO%=m,das of niopen; COiocdepn mpmnW: PY • nXpion MCMO•I Rios'.: =?p -a5 BE IT FURTHER RESOLVED: Certification to the FEL(s) listed above, as applicable, is subject to the following terms, limitations and conditions. The FEL(s) is the emission level declared by the manufacturer and serves in lieu of an emission standard for certification purposes In any averaging, banking, or trading (ABT) programs. It will be used for determining compliance of any engine in this family and compliance with such ABT programs. BE IT FURTHER RESOLVED: The listed engine models are conditionally certified in accordance with 13 CCR Section 1971.1(k)deficiency and fines provisions for certification of malfunction and diagnostic system) because the heavy-duty on -board diagnostic (HD OBD) system of the listed engine models has been determined to have five deficiencies. The listed engine models are approved subject to the manufacturer paying a fine of $75 per engine for the third through fifth deficiencies in the listed engine family that is produced and delivered for sale in California. On a quarterly basis, the manufacturer shall submit to the Air Resources Board reports of the number of engines produced and delivered for sale in California and pay the full fine owed for that quarter pursuant to this conditional certification. Payment shall be made payable to the State Treasurer for deposit in the Air Pollution Control Fund no later than thirty (30) days after the end of each calendar quarter during the 2013 model -year production period. Failure to pay the quarterly fine, in full, in the time provided, may be cause for the Executive Officer to rescind this conditional certification, effective from the start of the quarter in question, In which case all engines covered under this conditional certification for that quarter and all future quarters would be deemed uncertified and subject to a civil penalty of up to $5000 per engine pursuant to HSC Section 43154. eW AJr CUMMINS INC. I Now BE IT FURTHER RESOLVED: Except in vehicle appplications exempted per 13 CCR 1956.8(a)(6)(8), engines in this engine family certified under 13 CCR 1956.8(a)(6)(C) [30 g/hr NOx) and section 35.6.4 of the incorporated "California Exhaust Emissions Standards and Test Procedures for 2004 and Subsequent Model Heavy -Duty Diesel Engines and Vehicles" SHDDE Test Procedures) adopted Dec. 12, 2002, as last amended Oct. 12, 2011, shall be provided with an approved Certified Clean idle" label that shall be affixed to the vehicle into which the engine is installed. BE IT FURTHER RESOLVED: For the listed engine models the manufacturer has submitted the materials to demonstrate certification compliance with 13 CCR 1965 (emission control labels), 13 CCR 1971.1 (on -board diagnostic, full or partial compliance) and 13 CCR 2035 at seq. (emission control warranty). Engines certified under this Executive Order must conform to all applicable California emission regulations The Bureau of Automotive Repair will be notified by copy of this Executive Order. Executed at EI Monte, California on this 4 = day of October 2012. �Annette=ebert,ief Mobile Source Operations Division Reliability Driven' ATTACHMENT # 5 SUPPORTING DATA PROPOSER QUALIFICATIONS STATEMENT ITEMS A THRU J ie Beciccon J P. f T Y G R O U P 77 Water Street, 17th Floor New York, NY 10005 onebeacon,com October 30, 2013 Victor Valley Transit Authority 17150 Smoketree St. Hesperia, CA 92345-8305 2 Broadway, Room B19.130 New York, NY 10004 Re: Motor Coach Industries, Inc. RFP VVTA-2013-04 Furnishing and Delivering CNG powered Commuter Coaches and Low Emission Diesel Commuter Coaches Performance Bond This letter is to advise you that Motor Coach Industries, Inc. ("MCI") is a valued surety client of Atlantic Specialty Insurance Company. MCI remains in good standing and is afforded surety capacity of $20 million dollars for a single project and $30 million dollars in the aggregate. It is our opinion that MCI is qualified to perform the above captioned project ("Contract"), and we are prepared to favorably consider the performance bond required under the Contract for 5% of the award price schedule and otherwise in accordance with the Contract's Terms and Conditions. This letter is not an assumption of liability, nor is it a bid bond or a performance bond. It is issued only as a bonding reference requested from us by our client. Atlantic Specialty Insurance Company's decision to issue surety bonds on behalf of MCI will be subject to our standard underwriting including but not limited to acceptance of the financial condition of our client, contract terms and conditions, bonds forms and project financing. Atlantic Specialty Insurance Company is A rated by A.M. Best with a financial size category of XII and is included in The Department of the Treasury's Listing of Certified Companies. Sincerely, Atlantic Specialty Insurance Company za Lopez, Attq n� - n- pt One Beacon _ _,i /,.ICE 6 N Power of Attorney No. 2005110 KNOW ALL MEN BY THESE PRESENTS, that ATLANTIC SPECIALTY INSURANCE COMPANY, a New York corporation with its principal office in Minnetonka. Minnesota, does hereby constitute and appoint Harry A Dingier Jr., Jeannette Dominguez-Porrini, Airs Lopez, Marisol Moll", Rosalie A Monaco, David Moskowitz, Stacy Rivera, Ann Marie T(nerine, each individually If there be more than one named, its nue and lawful Anomcy-in-Fact, to make. execute, seal and deliver, for and on its behalf as surety, any and all bonds, recognizsnces, contracts of indemnity, and all other writings obligatory in the nature thereof. provided that no bond or undertaking executed under this authority shall exceed In amount the sum or: twenty-five million dollan(S25,000,000) and the execution ofmch bonds, recognisances, contracts of indemnity, and all other writings obligatory in the nature thereof in pursuance of these presents, shall be as binding upon said Company as if they had been fully signed by an authorized officer of the Company and scaled with the Company awl. This Power of Attorney is made and executed by authority of the following resolutions adopted by the Board of Directors of ATLANTIC SPECIALTY INSURANCE COMPANY on the twenty-fifth day of September, 2012: Resolved: That the President, any Senior Vice President or Vice-president (each an "Authorized Officer"), may execute for said in behalf of the Company any and all bonds, recognisances, contracts of indemnity, and all other writings obligatory in the nature thereof, and affix the seal of the Company thereto; and that the Authorized Officer may appoint and authorize an Attorney -in -Fact to execute on behalf of the Company any and all such instruments and to affix the Company seal therein; and the the Authorized Officer may at any time remove any such Anomcy-in-Fact and revoke all power and authority given to any such Anomcy-in- Fact Resolved: That the Altomey-in-Fact may be given full power and authority to execute for and in the name and on behalf of the Company any and all bonds, recognizatams, contracts of indemnity, and all other writings obligatory in the nature thereof, and any such instrument executed by any such Attorney -in -Fact shall bees binding upon the Company as if signed and scaled by an Authorized Officer an4 further, the Attorney -in -Fact is hereby authorized to verify any affidavit required to be attached to bonds, recognizanccs, contracts of indemnity, and all other writings obligatory in the nature thereof. This power of attorney is signed and sealed by facsimile under the authority of the following Resolution adopted by the Board of Directors of .ATLANTIC SPECIALTY INSURANCE COMPANY on the twenty-fifth day of September, 2012: Resolved: That the signature of an Authorized Officer and the Company seal may be affixed by facsimile to any power of attorney or to any certificate minting thereto appointing an Attomey-in-Fact for purposes only of execming and sealing any bond, undertaking, recognizance or other written obligation in the nature thereof, and any such signature and seal where an used, being hereby adopted by the Company as the original signature of such officer and the original seal of the Company, to be valid and binding upon the ^q WITNESS WHEREOF, ATLANTIC SPECIALTY INSURANCE COMPANY has caused these presents to be signed by an Authorized Officer and the seal of the Company affixed this ninth day of October, 2012. �dV INgV� W`Coppp0R4rF ° a SEAL m€ +,Y 1988 o j By STATE OF MINNESOTA A4by'bw wP+.aa HENNIPEN COUNTY fialdoo k/-, Paul H. McDonough, Senior Vice Presideru On this ninth day of October, 2012, before me personally came Paul H. McDonough, Senior Vice President of ONEBEACON INSURANCE COMPANY, to me personally known to be the individual and officer described in and who executed the preceding instrument, and he acknowledged the execution of the same, and being by me duly swom, that he is the said officer of the Company aforesaid, and that the seal affixed to the preceding instrument is the seal of said Company and that the said seal and the signature as such officer was duly affixed and subscribed to the said instrument by the authority and at the direction of the Company. 1, the undersigned, Secretary of ONEBEACON INSURANCE COMPANY, a New York Corpomtioa, do hereby certify that the foregoing power of attorney is in full force and has not been revoked, and the resolutions set forth above are now in force. Signed and sealed. Dated 3D&I it, of Q::b� . 2M3 This Power of Attorney expires October 1, 2014 .ZY IN.... 1rw� G,a a t�4 `pft1'OAAJFsni w SEAL 0. `U 1988 of ziZb Fit APb'a i Virginia McCarthy, Secretary Q Telephone: 212 -915 -BW Fm 2125135447 Websie: www wife corn Emelt Chi90 ,.FkkteF@Wilksw October 30, 2013 Victor Valley Transit Authority 17150 Smoketree Street Hesperia, California 92345 Attn: Mr. Ron Zirges, (COTR) RE: Insured: Motor Coach Industries, Inc. Project No. VVTA-2013-04 Dear Mr, Zirges: This letter is to confirm that Motor Coach Industries, Inc. ("MCI") currently has insurance in place that meets the requirements of Section 2.7.2 INSURANCE. Willis and MCI acknowledge that a contract will not be awarded by the Authority prior to the issuance and Authority's acceptance of the required certificate of insurance. Please note the attached certificate of insurance is issued as a matter of information only at this time, and confers no rights upon you. If you have any questions, please feel free to contact me at (212) 915-8146. Kind regards, Christopher Fletcher Assistant Vice President 1 Client Advocate Willis Risk Solutions Wifs 01 NY kc Ore Wald Fmn.M Cenfw 200 UMAY Sbeef. a lbw New Yak, NY 10261 October 30, 2013 Victor Valley Transit Authority 17150 Smoketree Street Hesperia, CA 92345 Attention: Mr. Kevin Kane, Executive Director Subject: Parent Guaranty — RFP No VVTA-2013-04 Dear Mr. Kane: Please allow this letter to confirm that in the event that Motor Coach Industries, Inc. is the successful proposer and is awarded a contract pursuant to the referenced RFP, its parent company, Motor Coach Industries International, Inc., will guarantee the performance of Motor Coach Industries, Inc. for all work to be perfonned and obligations undertaken in connection with such contract. MOTOR COACH INDUSTRIES INTERbIATIC04L, INC. Approved Signature: Name: Patrick Scully Title: Executive Vice President Sales and Marketing Reliability Driven' ATTACHMENT F ENGINEERING AND SERVICE ORGANIZATIONS Reliability Driven' COACH SERVICE ENGINEERING ORGANIZATION MCI supports its customers with a Fleet Support organization consisting of Technical Solutions Manager, five (5) Fleet Support Co-ordinators operating from our Louisville Kentucky facility and nineteen (19) Fleet Support Managers strategically located throughout the U.S. These Fleet Support Managers are highly qualified by education, experience in manufacturing, quality control and/or actual on -property coach maintenance operations. They are able to call on each operator on a regular basis, providing technical support. They are also fully qualified to aid the operator in processing warranty claims. Mr. David Bugenig, Technical Solutions Manager, will be assigned to your area to handle service support, warranty claims, etc, and can be reached at the following number Mr. David Bugenig Technical Solutions Manager Motor Coach Industries Limited. Phone(281)460-2849 Mr. Bugenig will make regular visits to your property based on a pre -determined schedule, to offer advise, assistance and new service information. The Fleet Support Managers are supplemented when needed by qualified personnel operating from the factory, including a Fleet Support co-ordinator to provide the communication link between the Field and Manufacturing, Quality Control and Engineering. In addition, technical writers continually update our Service publications including technical bulletins, maintenance and operating manuals. These individuals work closely with our product -engineering department to provide the latest information to the field. In addition to the Fleet Support Organization available to assist you, MCI carries a full line of parts and parts service through our strategicallyplaced Service Parts Department to service your coaches along with the many thousands of our coaches operating throughout the U.S and Canada. To further provide factory support, MCI has now implemented a 24-hour Toll Free number to provide all MCI operators with emergency assistance as may be required. 1-800-241-2947 Motor Coach Industries, Limited takes pride in providing full after market support to all our valued customers. Motor Coach Industries Macdonald, Jim LTS Exec Director -Engineering 6711 Engineering -Adm inStrdbn MCI, Ltd. LTD -Fort Garry Engineering Brienen, Aria LTS Manager - Tool & Mfg Proc 2315 ilgs & Fixtures MCI, Ltd. LTD -Fort Gerry Manufacturing Danielson, Brent LTS Director -Engineering 6711 Engineering -Adm lnstmoon MCI, Ltd. LTD -Fort Garry Engineering Ferris, Joe LTS Manager - Mfg Eng 5211 Manufacturing Engineering MCI, Ltd. LTD -Fort Garry Engineering Ramsay, Lawrence LTS Manager - Eng Mechanical 5120 Engineering -Mechanical MCI, Ltd. LTD -Fort Garry Engineering Danell, Russell LTS Manager - Eng Stand & ProC6410 Engineering-Standafds&Pro MCI, Ltd. LTD -Fort Garry Engineerig Dorge, Sylvia LTS Assistant -Admin Sr. 6711 Engineering -Ad m instraton MCI, Ltd. LTD -Fort Garry Engineering Ml, Wenhao (Michael) LTS Manager - Eng Electrical 5115 Englneenng-Electmai MQ, Ltd. LTD -Fort Garry Engineering Shesaf, Chen LTSTechnical AdViSor5r Mech 5120Englneering-Mechanical MCI, Ltd. LTD -Fort Garry Engineering Contents July 201 eX Motor Coach Industries Danielson, Brent LTS'Director -Engmeenng 6711 Engineenng-AdminSbation MCI, Ltd. LTD -Fort Garry Engineering Abdalla, Ibrahem Thatcher, Brent MCS Sr. Technical Advisor -Electrical C19 -New Product Engineering LTSTechnlcal Advisor Sr Mech 5125Engineenng-Protect MICE Schaumburg & Engineering I I MCI, Ltd, LTD -FOR Garry Engineering Contents July 201 Motor Coach Industries Y Contents July 20 ex Motor Coach Industries Mi, Wenhao (Michael) LTS Manager - Eng Electrical 5115 Engineering-Electdcal MCI, Ltd. LTD -Fort Garry Engineering Cordova Jr., Manuel LTS Designer/Modler 5115 Englneenng-Electrical MCI, Ltd. LTD -Fort Garry EnglneerN Fallorin, Jesse Mar LTS Engineer/Tech III - Elec 5115 Engineering -Electrical MCI, Ltd. LTD -Fort Garry Engineering Javier, Cherry LTSEnglneer/reChl-Elec 5115 Engineering -Electrical MCI, Ltd. LTD -Fort Garry Engineering Swan, Stephen LTS Engineer/rech lI -Elec 5115 Englneenng-Electrical MCI, Ltd. LTD -Fort Garry Engineering Chin, Bruce ITS Engineer/Tech III - Elec 5115 Engineering -Electrical MCI, Ltd. LTD -Fort Gam/ Engineering Ferrer, Pacholo LTSEnglneering Student 5115Englneering-Electrka MCI, Ltd. LTD -Fort Carry Engineering Lopez -Merl, Agustin LTS Engineer/Tech III - Elea 5115 Engineering -Electrical MCI, Ltd. LTD -Fort Garry Engineering Thiessen, Mlles LTSEngineer/rech I-Elec 5115Englneering-Electrical MCI, Ltd. LTD -Fort Garry Engineering Contents July 20 ex Motor Coach Industries Ramsay, Lawrence LTS Manager - Eng Mechanical 5120 Eng inecring-Mechmical MCI, Ltd. LTD -Fort Garry Engineerng Alarcon, Jorge Perez LTS Engineer/Tech 111 -Meth 5120 Engineering -Mechanical MCI, Ltd. LTD -Fort Garry Engineering Da rvill, Doug LTS Engineerrech lR-Meth 5120 Engineering -Mechanical MCI, Ltd. LTD -Fort Garry Engineering Law, Thomas LTSEngineer/Techll-Mech 5120Engineenng-Mechanical MCI, Ltd. LTD -Fort Garry Englneering Polyakov, Roman LTSEngineer/Techll-Mech 5120Engineenng-Meehmical MCI, Ltd, LTD -Fort Garry Engineering Westervelt, Craig LTSEngineer/rech II-Mech 5120Englneenng-Mechanical MCI, Ltd. LTD -Fort Garry Engineering Bjornsson, Cody LTSEnglneering Student 5120Englneering-Mechanical MCI, Ltd. LTD -Fort Gary Engineering Garton, Alvin LTS Engineer/tech lit - Meth 5120 Englneering-Mechanical MCI, Ltd. LTD -Fort Gary Engineemg Lazcano, Alvaro LTS Technical Advisor Sr Mech 5120 Eng Ineenng-Mechanical MCI, Ltd. LTD -Fort Garry Engineering Shtelman, Dmitriy LTSEnglneer/rechli-Mech 5120Englneenng-Mechanical MCI, Ltd. LTD -Fort Garry Engineering Young, David LTSEnglneer/rechll-Mech 5120Engineering-Mechanical MCI, Ltd. LTD -Fort Garry Engineering Contents July 20 ex Motor Coacn Industries Meadows, Shayne LTSSupenntendent 2120 Ad m In FTG MFG MCI, Ltd. LTD -Fort Garry ManufaCtumg Beischer, Dean LTS Supervisor - Production 1405 LT-Welding/IN-D-Line MI, Ltd. LTD -Fort Garry Manufacturing Dufault, Paul LTSSupervlsor-Productlon 1410LoWFrmeAssemb MCI, Ltd. LTD -Fort Garry Manufacturing Lafond, Dan LTSSupervlsor-Productlon 1425 Tdm/Lav Instal MCI, Ltd. LTD -Fort Garry Manufacturing Branquinho, Paulo LTSSupervlsor-Protluctlon 1430 Shell Paint/UC MCI, Ltd, LTD -Fort Garry Manufacturing Ivison, Darren LTSSupervlsor-Productlon 1415Upp Frme Assemb MCI, Ltd. LTD -fort Garry Manufacturing Martens, Ron LTS Supervisor-Protluctlon 1240MIsc Assem/Parc MCI, Ltd. LTD -Fort Garry Manufacturrg Contents July 201 ex Reliability Driven` ATTACHMENT G MANUFACTURING FACILITIES Reliability Driven MCI is regarded as the most capable manufacturer of coaches and commuter buses in North America given its history, depth and resources. MCI has been manufacturing coaches since 1933 and is the largest manufacturer of coaches in North America today. MCI has led the industry by building more than 25,000 coaches with over 6,600 of them in service with transit properties in the U.S. and Canada including 1,176 with NYCT. MCI has traditionally been the only Buy America compliant and Altoona tested Commuter coach manufacturer and has honed its vehicle offering to the specific needs of transit operators like NYCT. The precision to which MCI has developed its product for the transit Commuter market has resulted in the industry's lowest total cost of ownership product including acquisition, operating and support costs. MCI's D4500 product has over 6,000 units in active revenue service with some well over the 12 year FTA funded lifespan. The D4500's ability to extend beyond the 12 year benchmark can allow MassDot to extend capital dollars by allowing buses to stay in service longer. Several thousand employees are involved in every aspect of coach production including engineering, manufacturing, warehousing, quality control, administration, and after -delivery parts and service. Substantial investments have been made to provide the latest computer - controlled equipment, sophisticated machinery and modern manufacturing techniques. The MCI is preceded by a number of models through which continuous refinement and development has resulted in the proven systems that are the foundation of the MCI. These models developed a reputation for quality, performance, and reliability that have earned MCI coaches the highest resale value of any intercity coach available today. The reliability and acceptance of these coaches are also evident by the estimate that two-thirds of the intercity coaches currently on the highway in North America were made by MCI •MCI: A HERITAGE OF RELIABILITY w Am - 40000,F� opl. is Nul Reffability Driven Reliability, comfort and low cost of operation are just as important today at Motor Coach Industries as when Harry Zoltok founded FortGarry Motor Body and Paint Works Ltd. in • _ — v6 m- .r _ Winnipeg and designed his first 11 -passenger motor coach on a Packard chassis in 1933. MCI was right there at the dawn of modern mass transportation on North American roads.The company's earliest models had to go where passenger cars were few and far between and where rail lines were virtually non existent.That's an enormous responsibility for a manufacturer, and 80 years later, MCI remains Reliability Driven. CELEBRATING HISTORY 1930s Harry Zoltok Incorporated the Fort Garry Motor Body and Paint Works Limited in Winnipeg, Manitoba, and built the company's first motor coach, an 11 -passenger body on a Packard passenger car chassis. Later he designed his own chassis and manufactured the first complete coach for Grey Goose Bus Unes.The Model 150, a new transit -type coach with the windshield over the radiator, was introduced. 1940s On January 7,1941, the company changed its name to Motor Coach Industries Limited (MCI) and introduced the Model 50, a 33 -passenger coach. 19505 MCI developed more sophisticated models, including the MC -1, a revolutionary new coach design with many unique features including a heating system powered by engine cooling fans and a translucent roof providing a light, airy interior. 1960s MCI entered the U.S. market by establishing Motor Coach Industries, Inc. in North Dakota.The MC -6 Super Cruiser, which became known as the -Queen of the Highways: was developed for Greyhound Lines. 19705 MCI opened a parts distribution center named Universal Coach Parts to support U.S. customers' growing needs and for the first time exported coaches internationally to Mexico, Australia, Saudi Arabia and Taiwan.The MC -9 Crusader 11 was developed and became the best-selling coach in North America. 19605 MCI entered a new era of passenger comfort with the introduction of the 102C3 tour coach, featuring a higher roof, more spacious interior, fully paintable exterior surfaces and raised parcel Reliability Driven racks that provided greater visibility. Another new coach, the 102C3SS tour coach, featured durable stainless steel below the belt line. In 1989, Greyhound bought Hausman Bus Sales, which had been the sales arm of MCI new and preowned coaches in the U.S., along with Custom Coach, a coach converter in Ohio. 1990s With the passage of the landmark Americans with Disabilities Act, MCI produced a fully accessible coach including a new design wheelchair lift and accessible lavatory. MCI also introduced the 102EL3 Renaissance ) model, a completely redesigned coach that set new industry standards for luxury and offered a three-year warranty, the most extensive in the industry. 2000s MCI began its second century by strengthening its brand, In early 2000, the company unveiled a new logo and incorporated the MCI brand name into all of its business segments, establishing MCI Sales and Service as well as MCI Service Parts. Large public transportation agencies placed orders for MCI Commuter Coaches, totaling approximately 2,800 units in early 2000s, which included the largest -ever procurements of public transit vehicles. These milestones inspired several other important MCI innovations as well. MCI introduced the very first CNG Commuter Coach, delivering 77 units 1999 and 2000. In 2002, MCI also built the first hybrid -electric Commuter Coach, featuring a Cummins/ISL engine and an Allison EP 50 electric -drive hybrid propulsion system.Those coaches are still in operation. In 2001 MCI launched its MCI J4500 model and renamed its existing model lineup; the Renaissance became the E4500 and the D -Series 45400t and 40 -foot models became known as the D4500 and D4000, respectively. By the first quarter of 2004, the MCI J4500, celebrated for its ease of maintenance, stylish good looks and spiral entryway borrowed from the E4500, took its place as the industry's bestseller. In 2005, the restyled D4500 became the D4505 elevating its appeal in the tour and charter market. MCI accelerated its efforts in green transportation. In 2007, MCI unveiled models with the first generation of EPA -mandated clean -diesel engine technology that virtually eliminated particulate matter for a smoke-free exhoust.At the same time, the company began to publicize the environmental benefits of motor coach travel with its "Go Green, Go Coach, Go MCI" campaign. 2010s At the close of the new millennium's first decade, MCI's J4500 model continued as the industry's best-selling coach and its Buy America -compliant D4500 Commuter Coach and D4505 took the second and third top-selling spots in the industry's annual trend survey.The next generation of EPA -compliant 2010 clean -diesel engines arrived, promising near -zero emissions and fuel savings. As technology improvements to the coach models continued, MCI was upgrading its customer service technology as well, instituting online parts ordering, customer training webinars and Emergency Roadside Assistance customer support. Reliobility Dnven In 2011, MCI marked the 6,OOOth unit off its E/J assembly line and a first-ever order from the City of Los Angeles for 95 compressed natural gas (CNG) Commuter Coach vehicles. MCI has a long history serving public transit, and the data confirm how well the MCI Commuter Coach performs in both reliability and total cost of ownership. It offers 42 percent greater seating capacity than a comparable transit bus at a cost that's 15 percent lower per seat. Additionally, in recent independent testing, the MCI Commuter Coach proved itself to be 10 times more reliable than the closest competitor. MCI Today Growing Strategically, Growing Smart: On July 2, 2012, MCI announced the completion of its acquisition of Setra's U.S. and Canadian operations and established a strategic partnership with Daimler Buses (Daimler).These important moves gave MCI responsibility for sales and service support of Sets S 417 and Setra S 407 motor coach models and its pre owned coach inventory; the distribution of Setra and related genuine Daimler Buses parts; and operation of Setra's Orlando -based service center. Daimler also acquired a minority ownership position in MCI, forming an engineering, technology and manufacturing alliance as part of the transaction. Reliability DrivenTm: Marking its 80th birthday, MCI, which has made the majority of the 55,000 coaches on the road today, has rededicated itself to building the most reliable coaches in North America. The MCI — Reliability Driven'"" philosophy reflects the company's promise to design, build and deliver expertly engineered coaches with top-quality components, the latest safety and security features and unsurpassed parts availability and service. It's a philosophy that drives MCI's factories and offices,olike. There's a new corporate culture at MCI where our multi -facility ISO 9001:2008 certification assures that all plants share best practices ���UNto consistently tum out world-class products and marketplace innovations. We are working every day to make this company better. Reliable Coaches New Standards of Accessibility, Convenience and Comfort: The economy and environment are redefining the way people travel.That's good for MCI.Today's municipal and private transportation systems are looking to coach transport a flexible, affordable and green option for passengers who want to make the most of their money and time.That's why MCI is investing in the latest onboard amenities that turn riders into lifetime customers: Wi-Fi, power outlets and fiat - screen monitors to keep riders engaged, entertained and working. State -of -the art wheelchair lifts make accessibility and alternate transportation options possible for all. Renowned for their durability, dependability and curb appeal, the coaches ride on front -axle Koni shocks for a smoother, more responsive riclE+.The models feature an ACTIA multiplex system, brushless motors and stainless coolant tubes to maximize performance while delivering on the model's lowest -cost -of -operation ranking. Reliable Safety Safety First, Safety Always: MCI continues to lead the market in important safety and performance features. In addition to our strong and safe semi-monocoque stainless structure, MCI coaches feature Electronic Stability Control, SmartWaveg-Tire Pressure monitoring system and a fire suppression system. Popular safety options include three-point passenger seatbelts Reliability Driven and reverse sensing. Reliable Parts and Service Aftermarket Support That's Second to None: MCI is there around the clock, whether it's an emergency on the road, a question in the garage or online. While our presence is widespread, our services are focused. MCI provides one of the best networks of aftermarket support in the industry, with expert technical help, onsite training and the largest inventory of OEM parts for all makes of motor coach makes and transit buses. And they're all backed by MCI's commitment to quality and reliability. Coaches That are Cleaner and Greener. One fully occupied motor coach can displace as many as 56 passenger cars from crowded highways and when it comes to carbon dioxide (Co2) per passenger mile, coaches pollute far less than trains, planes or cars. But that's only where the good news starts. MCI's new coach models are powered by the next generation of clean -diesel engine technology that promises near -zero emissions and increased fuel savings. MCI is the only manufacturer to offer an intercity model, the MCI Commuter Coach, in diesel- electric hybrid and CNG configurations. MCI is proud that these low -emissions coaches are helping to reduce highway congestion and protect air quality. Coaches That Serve Virtually Every Customer and Purpose: No matter what the need, MCI has the coach. We serve the following markets: • Tour and charter • Scheduled and curbside service Public transit • Preowned Conversion/Entertainer Looks and Longevity: At MCI, being Reliability DrivenTm also means knowing how to refine a good thing. Customers have made the MCI J4500 a bestseller for nine years running and now MCI is giving operators new reasons to add the 2013 J4500 to fleets — including some eye-catching style changes. Working with BMW Group Designworks USA — the team that gave the market -leading J4500 its unprecedented curb appeal — MCI is refining and improving the look and feel of our luxury coaches in 2013 and beyond. R j The MCI Commuter Coach, in 45400t and 40 -foot versions, offers a comfortable, safe ride with ease of maintenance and low total cost of operation over many years.Today, MCI has options for clean commuting and offers the amenities that get people out of their cars and riding public transit. Some of the largest transit agencies in the country put the Commuter Coach model through millions of demanding miles. MCI is proud that the Commuter Coach continually stands up to the challenge. Quality for thelong distance commute; It's what makes MCI Reliability Driven. Reliability Driven • 0, M(:I Reliability Driven MCI Manut firing Facility Winnipeg, Manitoba, Canada }j"S9Sf 131 2�3� �0 • _. g� .lT I . -== I ��w w � 81 `'t���.._81 CC�F,p �• �^i-�-I M1J IAXT Wk 0 b 1m ID a I 1 s . .. c - c • - MCI Manufacturing Facility Pembina North Dakota USA WEST STUTSMAN STREET BUILDING 6 - MAIN PLANT iF rzc�acuwE ruxr+Vl+xwTuinx on+. 0 ]f lx� rybyq 1 --- 2 3 � I auun q o�ms "ixxlxxcx I �xm.x.mue •..H ixm x..n . 5 6 WEST .."�'.. 7 LINE i 8 9 0 10 db tl 12 1 W 14 t LU 15 I 16 1_ = 17 ....I �� NEGEIVIxG nn 18 CO p x PREYxW. = 19 omx 20IL 021 Ii U) 22 23 24 om5 yes, 9� Y I— W w of U) 1= rI I— 0) BUILDING 7 - PAINT SHOP 2 wmwx — 3 �� xEvnauo axnce 4 PAINTSHOP 5 D 1305 6 i 7 wu"run xmnxxuw: "i 8 /i g Reliability Driven' ATTACHMENT H SERVICE PARTS INFORMATION Reliability Driverf MOTOR COACH INDUSTRIES, INC. SERVICE PARTS AVAILABILITY MCI SERVICE PARTS, Inc. is the only authorized distributor of Motor Coach Industries, Inc. (MCII) original equipment service parts in the United State. MCI SERVICE PARTS, the largest supplier of aftermarket bus parts in the U.S., has been in the OEM coach replacement parts business since 1967. MCI SERVICE PARTS is staffed with knowledgeable field sales representatives, strategically located across North American, as well as an international staff of twenty professional customer service representatives, to assist with your coach parts needs; from on-line price & availability information to application assistance. Their Technical Service and on-site Engineering departments have computer access to, and maintain on file all of MCI's part number releases, change notices, drawings and bill of materials, to insure you receive the most current parts information. Also on staff is a trained Accident Coach Coordinator, responsible to insure timely receipt of body parts for damaged vehicles. Customer Service lines are open from 7 am to 7 pm CST Monday through Friday, and 8 am to 12 pm CST on Saturdays. A 24 hour toll-free fax line is available for order and other correspondence. Emergency 24 hour order service is also available for a nominal charge. MCI SERVICE PARTS maintains a large inventory of over 40,000 OEM bus parts - everything from rivets to front end frames. Along with their network of over 1,000 top quality vendors, MCI SERVICE PARTS offers the widest variety of parts for MCI as well as most other coach models. MCI SERVICE PARTS is also the exclusive distributor of COACHGUAREITm aftermarket parts. COACHGUARDT"( parts are designed to meet the needs of bus operators who are looking for parts at affordable prices, while maintaining original equipment product quality. COACHGUARDTm products are value priced, quality engineered alternative that meet or exceed OEM performance specifications. MCI SERVICE PARTS has five strategically located distribution centers across the U.S. and Canada, to insure the timely processing of your orders. Most orders are shipped with 48 hours of receipt - freight prepaid. New parts purchased from MCI SERVICE PARTS and installed on the operator's coach after the prescribed vehicle warranty period will be covered by the parts manufacturer's standard warranty or six month after date of purchase, whichever is greater. For more information regarding MCI SERVICE PARTS, Inc. and the services available, please contact them directly at 1-800-323-12382 or write: MCI SERVICE PARTS, Inc. Attention: Customer Service Department 7001 Universal Coach Drive Louisville KY 40258 Orders are shipped prepaid via the least expensive method. Air freight or other special routings will be shipped collect. i Reliability Driven" ATTACHMENT I QUALITY ASSURANCE PROVISIONS Reliability Driver' Ouality at the Source (OAS) MCI is currently implementing a revised quality system at its production facilities in Winnipeg and Pembina called "Quality at the Source" (QAS) which has been primarily used at the Toyota car company. QAS is an initiative building on our "Reliability Driven" theme. The key elements of QAS are: o The "voice of the customer" becomes the primary driving force. o Relationships with suppliers become closer. o Responsiveness to changing market conditions is enhanced. o The organizational structure decision making shifts from a vertical to a horizontal focus o The workforce is empowered. o Improved organization flexibility MCI's QAS model utilizes the following principles: o The quality standards for each operation must be ensured before parts are passed to the next operation o The line is stopped in the event of a defect o The reason for the defect is determined and the condition causing the defect is eliminated before continuing The above promotes the organization to go to all necessary lengths to correct conditions that cause production errors. The expected benefits to Victor Valley of MCI's implementation of QAS include: o The number of defects reaching the field drops due to improved first pass quality o Factory -floor organization is improved resulting in higher quality and more efficient assembly operations o Production flow times are optimized assuring more precise delivery timing Additional benefits to both Victor Valley and MCI include: o Workstations are well organized and neat, no idle parts or carts clutter the workspace o Fewer expeditors are needed o Storage racks for work -in -process are largely eliminated o Material handling is simplified, often with manual methods replacing automation Motor Coach Industries 11700 East Goa Read, Suite 300 1 Schaumburg, Illinois 601731847 2a5 20001866 624 2622 Tall Free w .mcicoach.com Reliability Driven - o Re -work stations are reduced o Scrap is significantly reduced, and the factory floor is much cleaner The Toyota Motor Company is credited with initiating the next production paradigm shift, originally referred to as the "Toyota Production System" (TPS). With later refinements and modifications, many by non -Toyota people and companies, this system has come to be known as "Lean Production." First and foremost, it is important to understand that "Lean Production" is not merely a set of practices usually found on the factory floor, but rather a fundamental change in how the people within an organization think and what they value, thus transforming how they behave. Within a "Lead' organization, everyone is focused on identifying and eliminating sources of waste and inefficiency. The six (6) strategic concepts of "Lead' (6) Relationships Based on Mutual Trr nd Commitment 5) Horizontal Organizational ocus Customer Value Relationship Building Lean Horizontal Organization Near Perfect Quality (4) Near Perfect Product Quality (1) Customer Value and Value Waste Minimization Flow and Pull (2) Waste Minimization a Continuous Improvemel (3) Flow and Pull Motor Coach Industries 11700 East Gaff Road, Suite 300 1 Schaumburg, lllirc is 60173 1847 285 2000 1 866 624 2622 Toll Free w .mciooach.com Reliability Driven" ATTACH M ENT J TECHNICAL PUBLICATIONS MCI WILL SUBMIT SAMPLE CD's OF OUR MANUALS WITH THE HARD COPIES OF OUR PROPOSAL. VICTOR VALLEY TRANSIT AUTHORITY PROPOSAL COMMUTER COACHES MCI D4500 Reliability Driverf October 31, 2013 Mr. Kevin Kane Executive Director Victor Valley Transit Authority 17150 Smoketree St. Hesperia,CA 92345-8305 Subject: Request For Proposals (RFP) No. VVTA-2013-04 Dear Mr. Kane: In response to Request For Proposals (RFP) No. WTA-2013-04, Motor Coach Industries, Inc. (MCI) is pleased to submit its RFP 2013-04 Price Proposal for Commuter Coaches. This letter and the documents attached hereto constitute MCI's Price Proposal. Attachment #1 Price Proposal for Coaches Attachment #2 Price Proposal for Component Options Attachment #3 Warranty Information Attachment #4 Optional Pricing Quotation We appreciate the opportunity to submit this bid and look forward to being called upon to fulfill your equipment needs. Sinc y, Patrick Scully Executive Vice President Sales and Marketing Moly Coach Industries 1200 Ease Oaldon Sweat I Das Plaines, Illinois 80018 1847 285 20001866 824 2822 Toll Free w .mtiooach.com 1.1.5.25 PRICE PROPOSAL Proposer shall complete the following form and include same in the Price Proposal package separate from the Technical Proposal submitted in response to this solicitation. By execution below Proposer hereby agrees to furnish the Commuter Coaches, related equipment, and services as specified in Victor Valley Transit Authority's Request for Proposals No. 2013-04 at the prices submitted in response to this solicitation. WTA - RFP 2013-04 PRICE PROPOSAL PROPOSER COMPANY NAME: Motor Coach Industries, Inc. STREET ADDRESS: CITY, STATE, ZIP CODE: AUTHORIZED OFFICER: COMPANY OFFICER TITLE: SIGNATURE OF AUTHORIZED CONTACT INFORMATION: OFFICE PHONE NUMBER: EMAIL ADDRESS: 200 East Oakton Street Des Plaines, IL 60018 Patrick Scully Executive Vice Presides -ICER.t a'A Dave Dorr 818-519-5032 Sales and Marketing dave.dorr@mcicoach.com Section 1 — Page 55 VVTA Solicitation No. 2013-04 Rev 4 Dated 8129113 1.1.5.27 OFFER COVER SHEET Proposer shall complete the following form and include same in BOTH the technical and price proposals. By execution below Proposer hereby offers to furnish equipment and services as specified in Victor Valley Transit Authority's Request for Proposals No. RFP 2013-04 at the prices set out in the pricing schedule. Street Address. 200 East Oakton Street City, State, Zip: Des Plaines, IL 60018 l Signature of Authorized Signer: G Patrick Scully Title: Executive Vice President Sales and Marketing Phone: 847-285-2354 Section 1 — Page 56 WfA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 11 1.1.5.29 COACH PROPOSAL PRICE SHEET (EXHIBIT NO. 1) VICTOR VALLEY TRANSIT AUTHORITY — JOINT AGENCY — COACH PROCUREMENT PROJECT — PRICE PROPOSAL SHEET BASE 1 2 3 4 TOTAL Prices shall be valid for 120 Days YEAR Option Option Option Option PROPOSED from the RFP Submittal Due ORDER Year Year Year Year PRICES Date. VEHICLE MODEL/TYPE 45 ft. $555.157 -bell PPI PPI ppl ppl $6,651,570.00 CNG PROPULSION SYSTEM driven cooling Belt Driven (Base Order Qty: 10) $679,957 - all clric $6,799,570.00 VEHICLE MODEL/TYPE 45 ft. $ NIA $ CNG PROPULSION SYSTEM PPI PPI PPI PPI PPI (Maximum Option Qty: 18) VEHICLE MODEL/TYPE 45 ft. $559,708 -belt $8,395,620.00 DIESEL PROPULSION SYSTEM driven cooling PPI PPI PPI PPI Belt Driven $8,617,620.00 (Base Order Qty: 15) $574,508 -el CWC VEHICLE MODEL/TYPE 45 ft $ $ $ $ $ DIESEL PROPULSION SYSTEM N/A PPI PPI PPI PPI PPI (Maximum Option Qty: 35) ALL REQUIRED VEHICLE $Included Included IncludedIncluded$Included OPERATIONS, & in coach in coach in coach in coach in coach in coach MAINTENANCE MANUALS, & price price price price price price OTHER DATA INITIAL OPERATOR and $Included in $ Included in MAINTAINER TRAINING coach pricE coach price RECURRENT OPERATOR and $3,000 $ $ $ $3,000+PPI MAINTAINER TRAINING (Two N/A per 16 ppl ppl PPI per 16 hours Sessions per option Order) hours OPTIONAL VEHICLE See Attache COMPONENTS OPTIONAL VEHICLE SERVICES See Attache SUB TOTALS PER COLUMN $ N/A $ ppl $ PPI $ PPI $ PPI $ PPl TOTAL PRICE PROPOSED FOR N/A ALL ITEMS Economic Price Adjustment for Option Orders: The Coach Option Order Prices shall be the Base Order Price adjusted by the Annual COACH (PPI) for the year in which the order is placed. Final price determination shall be made by the Lead Procuring Agency at time order is placed. The Lead Procuring Agency or its Assignee Procuring Agencies may procure either of the two vehicle types identified as required by their 5 year material needs. Placement of any Coach or Coach Related Option Item Orders is subject to available program year funding. Section 1 — Page 58 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 2 ,mom RFP 2013-04 1.1.5.30 COACH PROPOSAL VEHICLE OPTION ITEMS PRICE SHEET (EXHIBIT NO. 2) VICTOR VALLEY TRANSIT AUTHORITY — JOINT AGENCY — COACH PROCUREMENT PROJECT 2013 COACH PROCUREMENT OPTION ITEMS LIST ITEM Item Qty per Coach Item Price per Coach Total Price per Coach 1 Altro Style rubber flooring Included 2 RCA Style rubber flooring NIC 3 Wi-Fl Connectivity $500.00 $500.00 4 110 Volt Outlets $8,490.00 $8,490.00 5 Available Window Tints ENIA 6 Different Fuel Tank Configuration and Capacity Options 7 Restroom $2,350.00 $2,350.00 8 Bike Racks 1 $1,250.00 $1,250.00 9 Electronic Fare Boxes and/or Prewire Prewire Onl $875.00 $875.00 10 ITS Prewire Options 11 Video Surveillance System Options for System or Prewire Prewire Only $400.00 $400.00 12 CNG Fueling Valves and Defueling Ports if Options Included 13 Destination Sign Options Luminator NIC N/C 14 Lighting Options LED vs Fluorescent vs Standard, Additions, Deletions, etc. LED Standard Standard 15 Driver and Passenger Seat Options U SC 9100 AL N/C N/C 16 Transit Agency Paint Schemes TBD 17 Fire Suppression System Included 18 Wheel Chair Lift Options if Price Differential Ricon $1,400.00 $1,400.00 19 Power Assist Sliding Door if Available 1 $1,710.00 $1,710.00 20 Mirror Options Numerous $50 - $500 $50-$500 21 Any other options that are available which, if added, could cause a cardinal change to the proposal. $ Section 1 — Page 59 WTA Solicitation No. 2013-04 Rev 4 Dated "113 E3 1.1.5.22 WARRANTY FORM CERTIFICATION No. 12 - PROPOSAL No. VVTA-RFP 2013-04 Proposer, by its signature below, certifies that the following warranties shall apply to the coach and components: Complete Bus 1 year, 50,000 miles Engine (from engine manufacturer) 5 years, 500,000 miles Transmission (from transmission manufacturer) 5 years, unlimited miles Drive Axle 5 years, 300,000 miles Brake System (excluding Friction material) 1 year, 50,000 miles Body and Chassis Structural Integrity 3 years, 150,000 miles Body and Chassis Corrosion Fatigue 12 years, 500,000 miles Heat, A/C, doors, air compressor dryer, w/c lift, starter, alternator 3 years, 150,000 miles Signature of the ProWer's Authorized Patrick Scully Executive Vice President Sales and Marketing Name and Title of the Proposer's Authorized Official Motor Coach Industries, Inc. Company Name October 31, 2013 Date Section 1 — Page 51 WTA Solicitation No. 2013-04 Rev 4 Dated 8/29/13 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any price/cost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Reuter(cDmcicoach.com _ Proposer: Motor Coach Industries, Inc. Phone Number: 847-285-2105 Section: rosal is based on providing the following limited warranty. The proposed warranty time and mileages are with FTA and APTA standards . See attached for proposed warranty details Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev 4 Dated 8/29113 1.1.5.17 FORM FOR PROPOSAL DEVIATION CERTIFICATION No. 7 - PROPOSAL No. WTA-RFP 2013-04 The following form shall be completed for each condition, exception, reservation or understanding (i.e., deviation) in the proposal according to "Conditions, Exceptions, Reservations and Understanding" (Section 1.1.2.4). One copy without any pricelcost information is to be placed in the technical proposal as specified in "Technical Proposal Requirements" (Section 1.1.3.2) and a separate copy with any price/cost information placed in the price proposal as specified in "Price Proposal Requirements" (Section 1.1.3.5). Deviation Number: Email Address: Mark. Reuter(a)mcicoach.corn Number: Proposer: Motor Coach Industries Inc. Phone Number: 847-285-2105 " the applicable warranty period shall be extended by the number of days equal to the delay period" proposal is based on the deletion of the above paragraph as extensions from the original warranty cannot be provided gin •i, Fit�• replacement parts will have the remaining portion of the original warranty. Section 1 — Page 45 VVTA Solicitation No. 2013-04 Rev _A --_Dated 8129113 Reliability Driven` SELLER'S LIMITED WARRANTY Seller's Limited Warranty applies only to new coaches manufactured and sold by Seller for use in the territorial limits of Canada and the United States, including Hawaii and Alaska, excluding Puerto Rico, Guam and the Virgin Islands. This Limited Warranty is not assignable or otherwise transferable to subsequent owners of the Coach unless the subsequent owner provides timely written notice to MCI. Seller warrants for the Warranty Term herein specified that each new Coach, subject to certain exceptions, exclusions, and conditions noted below, will be free from defects in material and workmanship. This Limited Warranty applies only to defects discovered during the Warranty Term, which, except as noted in the table below, shall be twelve (12) months, unlimited mileage, from the date of delivery of the new Coach to Buyer. Complete Bus 1 year, 50,000 miles Engine (from engine manufacturer) 5 years, 500,000 miles Transmission (from transmission manufacturer) 5 years, unlimited miles Drive Axle 5 years, 300,000 miles Brake System ( excluding Friction material) 1 year, 50,000 miles Body and Chassis Structural Integrity 3 years, 150,OOOmiles Body and Chassis Corrosion Fatigue 12 years, 500,000 miles Heat, AIC, doors, air compressor dryer, w/c lift, starter, alternator 3 years, 150,OOOmiles Seller's Limited Warranty applies only to new coaches manufactured and sold by Seller for use in the territorial limits of Canada and the United States, including Hawaii and Alaska, excluding Puerto Rico, Guam and the Virgin Islands. This Limited Warranty is not assignable or otherwise transferable to subsequent owners of the Coach unless MCI receives either a properly completed Sale Notification form (a copy of which is in the Owner Limted Warranty Manual), or other documentation acceptable to MCI. Seller warrants for the Warranty Tenn herein specified that each new Coach, subject to certain exceptions, exclusions, and conditions noted below, will be free from defects in material and workmanship. This Limited Warranty applies only to defects discovered during the Warranty Term, which shall be twenty-four (24) months, unlimited mileage, from the date of delivery of the new Coach to Buyer. Buyer shall give Seller written notice of any defect occurring during the Warranty Term to which Buyer claims this Limited Warranty applies within thirty (30) days from the date such defect becomes apparent, specifying the nature of the claimed defect and the date it became apparent. Seller's obligation under this Limited Warranty is limited to (A) repairing or, at Seller's option, replacing free of charge any parts that, in Seller's reasonable opinion, have failed as a result of a defect in material or workmanship occurring during the Warranty Term under normal service conditions, provided that Buyer (i) has given Seller timely written notice of the defect; and (ii) upon Seller's request, has returned the defective part(s) to Seller, transportation charges collect; and (B) crediting Buyer for the labor cost incurred in the removal and replacement of any such defective part(s) based on (i) the number of hours designated by Seller to be required for such work, multiplied by (ii) 125% of the base rate for mechanical labor prevailing at Buyer's garage locale at the time of replacement, such base rate to have been previously approved by Seller. THIS LIMITED WARRANTY IS FURTHER SUBJECT TO CERTAIN ADDITIONAL TERMS, CONDITIONS, AND EXCLUSIONS THAT ARE ATTACHED HERETO AND HEREBY INCORPORATED BY REFERENCE AS EXHIBIT A. Buyer acknowledges that this Limited Warranty shall not apply to (A) any parts, components, materials, goods or services furnished or provided after Seller has completed its manufacturing processes with respect to the Coach; or (B) any routine maintenance repairs or replacements; or (C) normal wear and tear of the Coach; or (D) any other repairs or replacements that, in Seller's reasonable opinion, are required because the Coach or any accessories or other equipment comprising the Coach: (i) has been altered, modified, changed, reworked, or replaced in a manner that would likely affect serviceability in any respect; or Con't from previous page (ii) has been subject to abuse, neglect, or damage from an accident, or from intentional acts; or (iii) has not been serviced and maintained at reasonable intervals according to Seller's recommendations; or (iv) has been operated at speeds in excess of Seller's and/or any component suppliers recommended maximum speed; or (v) has had installed replacement parts not recommended by Seller and which have been substituted in such a way as to affect serviceability. ENFORCEMENT OF THE FOREGOING OBLIGATIONS OF SELLER SHALL BE BUYER'S SOLE AND EXCLUSIVE REMEDY AGAINST SELLER WITH RESPECT TO THE COACH. THIS LIMITED WARRANTY AND SELLER'S OBLIGATIONS HEREUNDER ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT WILL SELLER BE LIABLE FOR ANY OTHER OBLIGATIONS OR LIABILITIES, INCLUDING LIABILITY FOR ANY GENERAL, SPECIAL, DIRECT, INDIRECT, INCIDENTAL, PUNITIVE, ENHANCED, RELIANCE, OR CONSEQUENTIAL DAMAGES OF ANY KIND WHATSOEVER (INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFITS AND LOSS OF USE) WITH RESPECT TO THE SALE OR USE OF THE COACH. NO PERSON IS AUTHORIZED TO CHANGE OR OTHERWISE MODIFY THIS LIMITED WARRANTY OR ASSUME ANY OTHER LIABILITY ON BEHALF OF SELLER UNLESS SUCH CHANGE, MODIFICATION OR ASSUMPTION IS MADE IN WRITING AND SIGNED BY AN OFFICER OF SELLER. EXHIBIT A WARRANTY START DATE: Date of delivery of the new Coach to Buyer. ADDITIONAL EXCLUSIONSILIMITATIONS OF SELLER'S LIMITED WARRANTY Antennae Not covered for breakage. Batteries One Year pro -rated coverage provided only by battery manufacturer. Belts 50,000 miles (80,467 km) or 6 months (whichever comes first). Brake Rotors & Pads Not covered as a primary failure. Coach Conversion Parts, components, and services by third party not covered. Corrosion Coverage is subject to MCI's prior approval based on photographic evidence of claimed defect and repair quotation to be submitted by Buyer. Decals Covers only decals furnished and applied by MCI. Coverage is subject to MCI's prior approval based on photographic evidence of claimed defect and repair quotation to be submitted by Buyer. Electrical Motors Failure only; not brush replacement. Emission Controls and Emission System -related Parts Covered by MCI's Limited Warranty as and only to the extent they are required to be covered by a vehicle manufacturer pursuant to the laws pertaining to the warranties applicable to emissions controls or emission system -related parts in effect at the date of manufacture. Engine Covered only by engine manufacturer Engine Accessories Alternator, alternator belt tensioner, and air compressor covered only by the engine or the engine accessory manufacturer (unless MCI separately furnished and installed such engine accessory). Exterior Mirrors Covered for loss of function only, not breakage. Goods and/or Services Supplied by Buyer Not Covered. King Pins Bushings and seals not covered. Light Bulbs Other than LEDs, Not Covered. Luminator Destination signs Covered only by Luminator. Paint Covers only paint furnished and applied by MCI. Coverage is subject to MCI's prior approval based on photographic evidence of claimed defect and repair quotation to be submitted by Buyer. Passenger Seats and Seatbelts Covered only by seat manufacturer. Pinion Seals 300,000 miles (482,802 km) or 24 months (whichever comes first). Radius Rod Bushings 50,000 miles (80,467 km) or 12 months (whichever comes first). Refrigerant Not covered as a primary failure. REI Entertainment Systems Parts covered only by system manufacturer. Labor reimbursed by MCI. Shocks & Bushings 50,000 miles (80,467 km) or 12 months (whichever comes first). Sway Bar Links 50,000 miles (80,467 km) or 12 months (whichever comes first). Tires Covered only by tire manufacturer. Towing/Roadside Service 50,000 miles (80,467 km) or 6 months (whichever comes first), reimbursement Calls` limited to $750.001per occurrence and subject to additional conditions further explained below. Transmission Covered only by transmission manufacturer. Wheel Alignment Covered only during the first 25,000 miles (40,234 km), thereafter not covered as a primary failure; covered if alignment is necessary due to another covered warranty repair. Wheel Seals, Pre-set (hub, 300,000 miles (482,802 km) or 24 months (whichever comes first). wheel seal & bearings) Wheel Seals, Unitized (hub, 300,000 miles (482,802 km) or 24 months (whichever comes first). wheel seal & bearings) Wheel Studs Not Covered. Windows / Sash Assembly Not covered for breakage due to stone chips or other road hazards. Any coverage is subject to MCI's prior approval based on part return and/or photographic evidence of claimed defect, as requested by MCI. Buyer must also provide date code (located at bottom of window frame assembly, visible when opened or removed), window location (roadside or curbside of vehicle) and window position on vehicle. Wiper Blades Not Covered. `Towing/Roadside Service Calls. The towing/roadside service call must have been necessary due to a failure covered by the MCI Limited Warranty, and Buyer must have used good faith efforts to return the coach to service without using a towing service before requesting that the coach be towed. The costs of any towing/roadside repairs, and road service calls are not included within the scope of the Limited Warranty unless the failure requiring the roadside serviceltowing is covered by the Limited Warranty. Please consult the manufacturer of the engine, transmission, or other component not covered by MCI's Limited Warranty for any towing/roadside reimbursement such manufacturer may provide. n 4 Reliability Driven' OPTIONAL QUOTATION FOR VICTOR VALLEY CONSIDERATION Motor Coach Industries is pleased to offer the following additional options for Victor Valley consideration. Tire Pressure Monitor $ 1,500.00/Coach Driver Seat Options - Footrest (Manual) $ 36.00/Pass - Heated Seats S 200.00/Coach - Seat Alarm (Recaro) $ 95.00/Coach - Fabric $ N/C - Air Vent $ Not Available - Bolster Adjustment $ Not Available - Silicone Seat Cushion $ 400.00/Coach Side Windows (Framed) $ N/C Passenger Seat Options - Cup holder S 18.00/Pass - Headrest $ N/C - Footrest (Manual) $ 36.00/Pass - Footrest (Automatic) $ 61.00/Pass - Three Point Seatbelts $11,000.00/Coach APC System (Trapeze) $ 2,860.00/Coach Turn signal light in face of exterior mirrors $ 400.00/Coach